WELCOME Oil & Gas Industry Forum - Rockwell Automation · Oil & Gas Industry Forum 2012 ... Question & Answers 2 . ... The daily production rate of oil from each well increases to

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Rev 5058-CO900C 1

WELCOME – Oil & Gas Industry Forum Rockwell Automation – Automation Fair – November 2012

Beth Parkinson

Market Development - Global Oil and Gas

November 2012

http://oilandgas.rockwellautomation.com/automation-fair-2013

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Oil & Gas Industry Forum 2012

Welcome

Introduction Leveraging Technology to Reach Targets Eric S Fidler | Director Global Oil and Gas Solutions

CHCG: An Innovative Way to Enhance Oil Recovery Mei Lixin | CEO, Jiangsu Great River Otech

Nan Jiang – Rockwell Automation

Cloud-based Computing: Improving Remote Maintenance Josh Rabaduex | Controls Engineer, M.G. Bryan

Ted Hill | Global Business Development, Rockwell Automation

Process Automation Upgrade Improves Reliability and Reduces Downtime Gonzalo Maldonado | IT Infrastructure Supervisor, Petroamazonas

Javier Maldonado | IT Application Supervisor, Petroamazonas

Pablo Jarrin | Automation and Control Leader, Petroamazonas

Pedro Ramos | Automation and Control Leader, Petroamazonas

SCADA and Control Systems Cyber Security: Beyond the Hype and FUD Mark Fabro | President and Chief Security Scientist, Lofty Perch, Inc.

Question & Answers

2

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Rev 5058-CO900C

Leveraging Technology to Reach Targets Enhanced reliability through applied automation improved visibility and tools

Eric S Fidler

Director Global Oil and Gas

November 2012


Rockwell Automation at a Glance

Annual Sales: $6.2 billion

World Headquarters:

Milwaukee, Wisconsin, USA

Trading Symbol: ROK

Employees: About 20,000

Serving customers in

80+ countries

Leading global provider of industrial automation control and information solutions

4


Focused on Industry Challenges

5

• Increasing global demand

• Government regulation

• Increasing capital and operational costs

• Workforce experience shortages


Reliability, Where are you on the Journey?

The Aberdeen Group Defines best in Class Performance as:

91% Overall Equipment

Effectiveness

14% increase in operating margin vs. operating plan

1.6% or less Asset Downtime

Sub-bullet, Arial Narrow, 24pts Sub-sub-bullet, Arial Narro

Sub-bullet, Arial Narrow, 24pts Sub-sub-bullet, Arial Narrow,

20 pts

6

The effect of global economy on Asset Management


Reliability challenges Performance

7


Challenges That Can Affect Reliability

Operators are overwhelmed with Information

Enterprise level Operations struggle with “Big Data”

Subject Matter Expert pools are shrinking, resources need to be shared

Remote visibility empowered with live data is challenging

People entrusted to make decisions are not equipped to do so

People often focused in the wrong areas (good intent, wrong priorities)

8

Big Data Means all the Information you need is there…. Somewhere in your Organization


Actions That Drive Capabilities

Applied Automation

Network Loading Controller Loading Avoiding Bottlenecks System Design with process

sub system dynamics in mind Optimized System

Performance

Data

Dashboards Reporting Data Strategies Keep with firewall Leverage Services Cloud Computing

9


The Day Today

1. Jiangsu Great River Otech , CHCG: An Innovative Way to Enhance Oil

Recovery

2. M.G. Bryan, Cloud-based Computing: Improving Remote Maintenance

3. Petroamazonas , Process Automation Upgrade Improves Reliability and

Reduces Downtime

4. Lofty Perch, Inc, SCADA and Control Systems Cyber Security: Beyond

the Hype & FUD

10


CHCG: The innovate way to Enhance Oil Recovery

JIANGSU GREAT RIVER OTECH Co., LTD

Mei Lixin

CEO of Jiangsu Great River, China

2012/11/07

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 12

Agenda

Principle of Composite Heat Carrier Generator

About Us

Reference in China and future in the world

Advanced automation control technology

Principle of Composite Heat Carrier Generator(CHCG)

About us


Jiangsu Great River Otech Co. Ltd

13

Founded in August 2004, located in Jiangyin, Jiangsu Province, China

Provide the technical service to CNPC, CNOOC, SinoPec, etc(Top 4 oil companies in

China), and improve the efficiency of oil recovery with CHCG, the key technology of

Great River


Jiangsu Great River Otech Co. Ltd

Enterprise Certification

ISO9001 quality system certification CHCG has been certificated by Science Department High-tech enterprise in Jiangsu Province

14

Intellectual Property 8 invention patents 12 patents of utility model 2 trademark rights

Inspection & Certification Machinery Industry General Machinery Products Detection (MIGMPD) China Classification Society Certification (CCSC)


Agenda




About us


Background of CHCG

With much of the easy-to-produce oil already recovered from U.S. oil

fields, producers have attempted several tertiary, or enhanced oil

recovery (EOR), techniques that offer prospects for ultimately producing

30 to 60 percent, or more, of the reservoir's original oil in place. ---U.S.

Department of Energy (http://www.fossil.energy.gov/programs/oilgas/eor/index.html)

Three major categories of EOR:

Thermal Recovery Gas Injection Chemical Injection

16


Introduction of CHCG

Working Principle

Combustion of fuel, air and water in the sealing room Combustion in the sealing room and create CHC

Inject CHC into the oil well with high pressure

and high temperature

17

Model I、Model II、Model III

Buddle Model

Flexible carrier flow rate From 1200Nm3∕h to 3600Nm3∕h

Great River/复合热载体提高原油采收率技术~3.avi


Introduction of CHCG

Mode FDL/FDH FEL/FEH FFL/FFH

Pow

er

Voltage(V) 380

Frequency(Hz) 50

Power(Kw) 550 1100 1650

Max output pressure

(Mpa) 30

Oil well Depth range (m) 300 ～3000

Temperature of Heat carrier

(℃) 120 ～350

Max air flow rate (Nm3∕h) 1200 2400 3600

Max delivery pressure of

compressor (Mpa) 25 25 25

Max fuel flow rate (l∕h) 125 250 375

Max gas flow rate（Nm3/h） 110 220 330

Heat carrier flow rate (t∕h) 1～5.6 1～11.2

（+8） 1～16.8

Oxygen Remains﹪ <2

18

Oxy remains% <2 increase the safety of CHC injection

High temperature: 120-350℃

High pressure: 30MPa (rocket engine: 20MPa)


Character of CHCG

Composite heat carrier is mainly composed of CO2, nitrogen and steam

with high temperature and high pressure;

All of CHC after combustion will be injected into the oil well, and zero

carbon emission to the environment;

Three main ingredients of CHC have the different effect in the oil layer;

Special chemical ingredient of CHC will strengthen the performance of

EOR greatly;

19


Leading Technology of CHCG

Advanced combustion technology in the sealing space

IP for the critical sealing and the supercritical sealing combustion technology

Control of the oxygen remains in CHC under high-pressure combustion

Precisely control the combustion of CHC, and ensure oxygen remains under 2%

Usage of crude oil as fuel

Solve the problem of the coking during the combustion of crude oil

Explosion proof equipment of Composite Heat carrier(CHC)

20

Realize zero carbon emission to the air

Provide the easy-to-find fuel

Increase the safety level during CHC injection

Allow the application on offshore oil platform


Agenda

Advanced Automation Control Technology


Principle of Composite Heat Carrier Generator

About us


Challenge of Automation Control System

High requirement to the reliability of control system

Explosion proof requirement for the control system

Heat conduction of explosion proof cabinet of driver with the limited size

Global support & service

Easy maintenance, remote access

22


Automation Control System of CHCG

Rockwell Automation, the world famous industrial automation company, develops the total solution for CHCG together with Great River

23


Rockwell Automation: best choice for Great River

High Reliability

MTBF over 200,000 hours

Environment temperature permission

Total solution of Explosion proof & Heat conduction for the driver system

Global support & service

Remote access, easy to maintenance


Agenda




About us


Reference in China with significant performance

Main customers

Suitable reservoir

Light oilfield Heavy oilfield Low permeability Oil reservoir

26



Significant performance

In heavy oilfield, compare with regular steam inject, the oil recovery ratio increases

10%-15% after CHC injection. The production rate of oil from each well is 6.6 times

than original production rate.

27

10%-15% 6.6


During thermal recovery on B28h, B29m oil well, CHCG Model ∥ runs stably, which meet the thermal recovery requirement.

Application of Explosion proof CHCG in offshore heavy oilfield(Nanbao

#35-2 oilfield)

CHCG application in offshore oilfield in the first time

Meet the explosion proof requirement in offshore oilfield

Heavy oil field: viscosity 196~2010 MPa.s, reservoir depth:1700m

The daily production rate of oil from each well increases to 66 Nm3 from 10Nm3, the

annual production rate gets to 24,000Nm3.



www.rockwellautomation.com

Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn.

Rev 5058-CO900C

Thank you for your participant!

Please contact us:

Mr. Mei Yizhong.

+86 139 1239 6699


Global Trends in Information Systems and Solutions

Josh Rabaduex

Director of Engineering

M.G. Bryan

Ted Hill

Director, Global Business Development

Rockwell Automation


Agenda

Customer Solution – M.G. Bryan

The Cloud

Technology Trends


Technology trends…

We are living in the future…


Technology Trends…

Over the last few years there has been a dramatic change in „how‟

people compute…

Internet access is broadening…

Windows share of internet –connected devices

Other trends…

HTML5

Tablets

Social Media

Apps beat Web…


Mobile Phones

http://www.smartinsights.com/mobile-marketing/mobile-marketing-analytics/mobile-marketing-statistics/


Here comes the Cloud?

Gartner 2011


The Digital catalysts

Processing power

Computer processing

power doubles every 18

months.

Bandwidth

Digital bandwidth is

doubling faster than

Processing power

Storage capacity

Digital data storage is

doubling every 12

months.

41

(retail value? ~ $34 trillion)

Connectivity

3

4


Agenda

Customer Solution – M.G. Bryan

The Cloud

Technology Trends


M.G. Bryan - Customer Collaboration

44

Situation

OEM for oil field equipment produces

trucks for frack campaigns. Target

production of 10 trucks/week; ramping

up to 500 trucks/year

Each truck runs for 5000 hours before

an engine rebuild; and consumes

filters every 8-12 hours

Needs visibility into consumables on

equipment in the field

Doesn‟t have an IT infrastructure

Doesn‟t want to buy software or

hardware, doesn‟t want to maintain it

How do we help them?


Quality Assurance

• Batch record

• Leak test data

• Lab sample

Is a truck just a truck?

Process Control Engineer

• Pressure

• Flow

• Speed

Production Manager

• Volume pumped

• Product throughput

• Operation history

• Power consumed

Maintenance Manager

• Running hours

• Performance spec

• Work Orders

• Spares on hand

• Maintenance date

Process Engineer

• Related equipment

• Rating

• Vibration data

Asset Manager

• Purchase date

• Cost

• Warranty

• Manufacturer

• Engineering specs

Control System/HMI

Historian

Asset

Database

ERP, LMS, SQL

Database

Maintenance

Management

System

45


M.G. Bryan – Case Study / Demo


M.G. Bryan – Case Study / Demo


M.G. Bryan – Rockwell Solution

48

Rockwell Cloud Platform

Cloud Gateway

Drivetrain,

engine and

process data


High-value, differentiated solution for MGB and their

customers

Real time visibility of truck, fracking KPI‟s, & location

Supply usage-based consumables to trucks

Create accountability for truck maintenance

Ensure maintenance is done

Avoid over/under PM‟ing

Zero Infrastructure to maintain – scales from 1 truck

to x trucks

Same solution for new trucks and for truck retrofits

Enable new, value-added services for OEM (and for Rockwell)

APM Benefits & Value to MG Bryan

49




Thank you


Process Automation Upgrade Improves Reliability

and Reduces Downtime

Gonzalo Maldonado | IT Infrastructure Supervisor, Petroamazonas

Javier Maldonado | IT Application Supervisor, Petroamazonas

Pablo Jarrin | Automation and Control Leader, Petroamazonas

Pedro Ramos | Automation and Control Leader, Petroamazonas


Agenda

Overall benefits

Solution Selection Criteria and/or System Evolution

Business and Technical Challenge

Company Overview


Company Overview

Business Portfolio

Our operations are located in the Amazon Region and the main headquarters offices in

Quito (Ecuador´s capital city)

Main activities are Oil Exploration, Development and Production

Petroamazonas was legally named as a public company in Abril of 2010

In the past three years Petroamazonas received 3 new operation areas or blocks: B7,

B21 & B18 and is developing the Block 31 (ITT) during this year.

Contribute around the 32% of the entire oil national production

Daily average oil production 148.000 BOPD

57


Company Overview

58


EPF - Eden Yuturi Field (BLOCK 12)

EPF (53K BOPD)


CPF - Indillana Field (BLOCK 15)

CPF (39KBOPD)


Agenda

Overall benefits



Company Overview



Background and issues

In May 2006, Blocks 12 (EPF) & 15 (CPF) operation was transferred to Ecuadorian Government

RSView32 infrastructure was transferred to IT and Automation teams as black-boxes; which was a potential risk for the operation of both Fields (CPF & EPF)

All the base PLCs installed in the field are Allen-Bradley such as Controllogix, CompactLogix and PLC5.

Known issues: Physical servers out of warranty (obsoletes)

Operative systems (Win 2000) out of support

Missing licenses and/or duplicate serial keys

RSView32 platform not stable

Final users reporting issues permantently

63



Business Challenge

Keep production levels (100K bopd) and try to increase them supported by people and technology

Increase availability, reliability and maintainability of monitoring and control system SCADA to avoid downtimes and improve the operation of both plants and well islands.

Provide an stable system for key users to monitoring production process of both plants.

Provide real-time and historical information to end-users responsible to make operative decisions on both Fields.

Provide a robust, manageable and secure HMI application supported by an stable networking, hardware and software infrastructure.

64



Technical Challenge

Support the operations requirements with the latest technology available in the market

Define new standards for Automation platforms ¿Keep Rockwell Automation products? ¿Why? A new system design based on the final decision Prepare, configure, test and deploy the new HMI Technical knowledge (training in new features) for IT and Automation Roles and responsibilities for IT and Automation teams Reduce risk and impact to the operations during the upgrade Standardization of the control systems from PLC5 to Contrologix

Platform and Logic Solver. Integration of MVD´s (Water Injection) to FactoryTalk through Logix

platform.

65


Agenda

Overall benefits



Company Overview


Solution Selection Criteria

Solution Criteria

Petroamazonas required to: Upgrade from Rsview32 to Factory Talk to the entire HMI platform

Implement a redundant and reliable HMI system

Implement one project for both fields applying the same technology and

processes. Note: two separate applications, one for CPF and other for EPF

Implement an audit tool to keep track of changes at the PLC programming level

Apply Active Directory authentication into the HMI log in process in order to

increase security levels to the application

System compatible with new PAM EP standards (Cisco, HP, Microsoft, etc.)

Work directly with Rockwell Automation Ecuador instead of solution providers

Work with an interdisciplinary team (IT Infrastructure, IT Technical Applications,

and Automation Engineers) plus Rockwell Automation consultants

67


Solution Selection Criteria

Solution Criteria

Petroamazonas made a decision to continue with Rockwell Automation products and solutions based on: Standardization process, including new projects

Less impact to the operation of both Fields (CPF & EPF)

New tools for data management trending and Data/HMI/OPC servers

Certified platform with Petroamazonas current hardware (HP, Cisco, Microsoft,

McAfee, EMC, Citrix, etc)

Fulfill IT and Automation users requirements

Rockwell Automation Support (Service Order direct with Rockwell Automation

Ecuador)

Rockwell Automation offer a license swap for the majority of RsView32 and

control software licenses

68


System Evolution

Project plan and phases:

2008: Initial meetings with Rockwell Automation team, evaluation of the product and

architecture design startup

Internal decision service order approval, notification to Rockwell Automation

and coordination between both companies

2009: Project execution (January to December) according to project plan

2010: Both systems were moved to production

2011: Stabilization and adjustment service was approved

PAM EP made a decision to virtualize the platform including several

adjustments to networking configuration and systems capacity

69


System Evolution

Final Architecture

71


System Evolution

Networking Architecture

72


System Evolution

Final Architecture

Virtualization optimization

73


System Evolution EPF/CPF Architecture Plant Summary

DISPLAYSHMI

SERVERS

HMI

TAGS

DATA

TAGS

DATA

SERVERS

HISTORIAN

TAGS

EPF BLOCK 12 55 500 2 121K 105K 18 8K

CPF BLOCK 15 59 396 1 62K 45K 10 5K

HMI DATAPLC

CONTROLERS

VMWARE

SERVERS

HMI SCADA

CONSOLES

ENGINEERING

STATION

MONITORING

STATION

EPF BLOCK 12 55 16 6 3 1

CPF BLOCK 15 59 12 3 2 1

PLC

CONTROLERS

HARDWARE


EPF - Control Room (BLOCK 12)


EPF - Plant Overview FTV (BLOCK 12)


EPF - Leak Detection System


EPF - Architecture Plant Overview


CPF - Control Room (BLOCK 15)


CPF - Plant Overview FTV (BLOCK 15)


CPF - Electrical SCADA Overview


System Evolution

System Evolution

Validation of current networking and domain architecture by Rockwell Automation Engineer. A few recommendations to be considered in the future

Servers virtualization using VMWare New Redundant Data/HMI Servers Distribution added to provide

enough system capacity A new storage (HP P-2000) to provide servers redundancy Migration from Microsoft SQL Database to FTK Historian Migration to a Cisco Metro Ethernet infraestructure (Layer 3) System monitoring through HP Software tools PLCs redundant configuration and upgrade to Controllogix Platform in

some cases

82


Agenda

Overall benefits



Company Overview


Overall Benefits

Overall IT Benefits

Less downtime issues in both plants directly related with HMI application and processes

VMWare benefits: faster delivery of application servers (~ 10-15 minutes per server vs 30-45

days for a physical box), high-availability of the servers (99.8%), 0 downtime issues during

servers maintenance activities (V-Motion), etc.

Reduction of CAPEX in servers purchase orders (~70%) physical boxes vs VMWare

100% compliant platform with PAM EP standards: Cisco, Microsoft, VMWare, McAfee, EMC

Storage optimization using FTK Historian versus SQL database ~ 100 GB with Historian

vs 500 GB with SQL for the same database (relation 1 to 5)

7 x 24 x 365 access to Techconnect technical support

Rockwell Automation Architecture ensures a scalable, flexible and reliable solution for new

production facilities in other Blocks.

85


Overall Benefits

Overall Automation Benefits

Real-Time and historical trending connectivity to FTK Historian using directly data servers connection,

improving of global performance of trending, now faster and avoiding overload of HMI application and

network delays with SQL configuration (Loading Time of Trends in relation 1 to 5 faster)

Expand automation architecture to facilities of new oil producing assets, guarantying interoperability and

maintainability of the whole platform.

Allows editing of the program even if it is running from any computer connected to the network and with

multiple developers (Before Rsview32 did not allow online changes and only from Main Server)

Through of Contrologix Platform, the integration have been easier and successful. Data management

tools work better with Factory Talk Studio such as online controller tags and data server distribution.

Using Asset Centre, there is a good management of automation programs and documentation related, an

audit program, disaster recovery issues scheduled and access from anywhere of the main PLC programs

Initial Startup and Navigation of entire Factory Talk Application is faster in relation 1 to 3 than RSview32

Application.

86


Next Steps

Next Steps

New HMI applications for other PAM EP Fields are being designed using CPF/EPF architecture as a base, including Rockwell Automation recommendations and best practices.

Upgrade to the latest Factory Talk versions including migration to Win 7 and Windows Server 2008 servers

Improvements to networking and domain architectures according to Rockwell Automation recommendations

Vantage Point and View Point, starting on Electrical SCADA implementation that was developed for CPF (Block 15)

FactoryTalk AssetCentre Calibration Management PlantPax for new projects Block 31

87


Questions

[email protected]) [email protected]) [email protected]) [email protected])

mailto:[email protected]


mailto:pablo_jarrí[email protected]



SCADA and Control Systems Cyber Security:

Beyond the Hype and FUD

Mark Fabro | President and Chief Security Scientist, Lofty Perch, Inc.




Rev 5058-CO900C

Questions & Answer Roundtable

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Rev 5058-CO900C 91

Thank You – Oil & Gas Industry Forum

http://oilandgas.rockwellautomation.com/automation-fair-2013

Documents

WELCOME Oil & Gas Industry Forum - Rockwell Automation · Oil & Gas Industry Forum 2012 ... Question & Answers 2 . ... The daily production rate of oil from each well increases to