Pemex: Oil & Gas Facility Reduces System Startup from Days to Minutes with PlantPAx

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Oil’s movement at dehydration & desalting process. Migration to PlantPAx System

Nestor Cautiño

Business Manager-ICG Group

November 2014


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Agenda

End user gained benefits

Implementation challenges and learned lessons

Proposed solution

Project’s goals

About the End User & ICG Group


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About the End User

Petroleos Mexicanos better known as “PEMEX”

It’s a state owned company with a reported

annual revenue (as of 2012) of $128 billion

dollars. It’s the largest company at Mexico. It

produces about 2.5 MBPD., and 6,385 MCFPD.

The job site

It’s a Marine Oil Storage, Transportation and

Distribution Terminal, named Dos Bocas and

known as “TMDB”.

The TMDB receives crude Oil and Gas coming

from different offshore rigs at Mexico’s Gulf.

The project it’s related to oil’s dehydration &

desalting process in order to meet certain API’s

gravity and production specifications.


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About ICG Group

ICG Group S.A. de C.V.

Founded on 2003, we are a privet owned company with a reported annual revenue (as of 2013) of $5 Million dollars. Located at Mexico’s Southeast and focused mainly at Automation, Control & Power Solutions for the Oil & Gas industry.

ICG Group it’s part of the RA’s Recognized System Integrator Program.

Our main customers list includes companies such as PEMEX, Solar Turbines, Rockwell Automation, ICA Flour, Celanese and local O&G EPC’s.

Our experience includes control systems and power solutions for applications such as crude oil transportation, separation, blending, burner management, residual water treatment, dehydration & desalting processes.


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Project’s History -The production-

Production challenges:

Oil coming from offshore wells has

increased water and salt content. This

affects the production quality, which leads

to economic penalties, this conditions

causes damage or wearing to processes

& transportation assets.

The product is a heavy Mayan Oil,

(API’s 22º.)


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Project’s History - The process -

The complete process:

Intended to meet market requirements by maintaining certain levels of salt and water content.

The process includes the following stages: 1st stage dehydration & heating. 2nd stage desalting. Residual process water treatment. Residual process vapors handling.


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Project’s History - Issues & Goal -

Control system’s current issues:

Complicated failure diagnostics.

Redundancy backup doesn´t work.

System’s design and programming

isn´t friendly enough for

maintenance.

HW & SW obsolescence.

Our project’s main goal is to ensure the continuous oil transportation or movement throughout the process.


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Project’s History - Installed base -

Existing control system:

Based on redundant CLX55.

Flex I/O as remote chassis.

ControlNet network.

RSView32 as HMI.


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Goals

Project’s goals includes:

Reduce down time risk, by

improving the overall availability

and reliability.

Extend life cycle by migrating to

current technologies.

Maximize the use of current

installed base (phased migration).

Regulations compliance.

Improve maintenance & diagnostic

capabilities.

Reduce learning curve for operators and maintainers.

Production continuity


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Initial challenges

Use the latest technology but at the same time optimize the use of existing installed base.

Communication with different 3rd party vendor’s devices.

Pepperl + Fuchs (Barriers)

K-tronix (UPS)

Implementation of different networks Ethernet

FF

Modbus

3D HMI graphics implementation, while keeping consistency with existing design.

(3D HMI Sample)

(2D HMI Sample)


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Proposed solution

Phased migration from CLX 55 series architecture to PlantPAx system.

For budgetary and planning reasons some pumps at stations CB 1 & CB 2, will

keep using the existing Flex I/O, but CPU’s & redundancy systems will be

migrated. Next projects phases will take advantage of RA’s PlantPAx scalability.

Increased system’s availability and reliability

PlantPAx system based on CLX 73 series controllers.

Enhanced Redundancy System based on 1756-SRM2 modules.

Redundant power supplies.

Redundant HMI servers.


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Proposed solution

Improve communications trough network technologies

Ethernet IP instead of ControlNet at the control layer.

FF segments instead of point to point connection for field instruments.

Fiber optics for safety compliance at field devices.

Upgrade HMI graphic quality and make it user friendly

FT Studio will be used to create HMI easy to read, understand and operate.

HMI graphics migrated to 3D type., and meeting customer’s regulations.

Implementation of Historian server

Users now can view individual historical data for each pump and process.

The data capture helps to improved analysis and decisions.

Provides the ability to correct sources of inefficiencies quickly.


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Proposed system’s architecture


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Implementation challenges

Communications:

Fieldbus diagnostic info uploaded and read at engineering and operator’s stations.

Hardware:

3rd party Fieldbus vendor integration.

Software:

Redundant server setup.


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System’s implementation benefits

Reduced system’s design time. Add-On Instructions

Faceplates

Open protocol communications.

Connectivity to process field networks.

Electronic selection tools for quick system layout.

From the implementation stage of the project we were able to get the following benefits, which at the end of the day represents savings.


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Customer’s gained benefits

Process uptime

Through system's availability & reliability improvement.

Redundancy at servers,

controllers, power supplies.

Down time reduction

After failure, a system’s recovery time improved from 1 day to a couple of hours.

Factory Talk Alarms & Events

Historian Server.

PACTware.


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Customer’s gained benefits

Improved maintenance

Process variables are being recorded in real time.

Maintenance tasks can be programed in a predictive way.

System lifecycle

Although user is on a phased migration plan, the critical system assets had been upgraded to the markets latest technology.

HMI useful and friendly design.

Graphics were migrated from 2D to 3D design.

It’s easier to navigate, read and get data for analysis to make better business decisions.


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Deliverables samples -HMI-

BOMBAS

GA-3100A

GA-3100B

GA-3100C

MB-1

MB-2

MB-3

MB-4

MB-5

MB-6

MB-7

MB-8

CB2 - IO CB1 - IO

TABLERO

GA-3300F TABLERO DE

GA-3100F

FIELD BARRIER

LINKING

DEVICE

CLX

FIBRA OPTICA

UTP

SWITCH

ETHERNET

FB

ESTACIÓN DE

INGENIERÍA

SERVIDOR

HISTÓRICOS

SERVIDOR FTVIEW

REDUNDANTE

ESTACIONES DE OPERACIÓN

UPS

CB1 - IO CB2 - IO RE

D C

ON

TR

OL

NE

T A

CA

SA

DE

BO

MB

AS

1

RE

D C

ON

TR

OL

NE

T A

CA

SA

DE

BO

MB

AS

2

PANEL VIEW CB2 PANEL VIEW CB1

A INSTRUMENTOS A INSTRUMENTOS

PLC´S

REDUNDANTES,

CONTROLLOGIX

DE LA CASA DE

BOMBAS 1

CLX CB2 PLC´S

REDUNDANTES,

CONTROLLOGIX

DE LA CASA DE

BOMBAS 2

PLC´S

REDUNDANTES,

CONTROLLOGIX

DE LA UPR-01B

RED

FDDI

NIVEL SUPERVISIÓN

NIVEL CAMPO

BOMBAS

GA-3300A

GA-3300B

GA-3300C

GA-3300D

GA-3300E

GA-3300F

BOMBAS

GA-3100D

GA-3100E

GA-3100F

BOMBAS

MB-1

MB-2


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Deliverables samples -Panels-


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Questions ?

Nestor Cautiño

Business Manager – ICG Group

November 2014

Technology

Pemex: Oil & Gas Facility Reduces System Startup from Days to Minutes with PlantPAx