Smart Oilfield and Platforms Case Study – ONGC Enterprise wide SCADA

Agenda of Presentation Present Oil Field and Platform Operation Practices Concept of Smart Oilfield and Platforms Smart Oilfield and Platforms – Detailed View Instrumentation Automation Communication Applications Business & Scientific System Integration Case Study – ONGC Enterprise wide SCADA

Present Operation Practices Following are the issues faced by the Operating companies. Skilled manpower shortage Accuracy and Efficiency of processes Data Validation, Recording is an issue Insufficient history information for the Analysis and comparisons or biased information No mechanism to identify the pipeline leakages as well as the thefts Inaccurate flow measurement due to non use of standard flow measurement practices No online water cut measurement resulting in delays in corrective action No control in the separator makes the process unstable. Excess energy consumption due to improper temperature control at heater treater Safety work practises Manual reporting and Calculation

Agenda of Presentations Present Oil Field and Platform Operation Practices Concept of Smart Oilfield and Platforms Smart Oilfield and Platforms – Detailed View Instrumentation Automation Communication Applications Business & Scientific System Integration Case Study – ONGC Enterprise wide SCADA

Concept Of Smart Oilfield and Platforms The Smart Oilfield and Platforms Provide Well head telemetry supervision and control Provide Real time Monitoring and Control of Manned, Unmanned and Remote location at centralises place. Provides minimum Human Intervention in day to day operations Provide Stabilised production and Transportations process as well as Optimisations Prevent transportation losses in Pipelines Provide real time data Consolidation, Recording and storage for the analysis for future evaluations Reduce the delay in decision making via online measurements of critical parameters such as Water cut, Gas Composition etc Provide all real time KPI ( Key Performance Indicators ) to Corporate level/ Board level for quick decision making Standardisation on SCADA, devices and communications simplifies training and maintenance Significantly reduces downtime by being proactive in operating abnormal conditions

Concept Of Smart Oilfield and Platforms To Convert an Oil Field to Smart Oil Field following are major contents Suitable Instrumentation on well head and Production, Storage and Transportation facilities for real time measurement as per the standard guidelines. Automation system to monitor, control the Production facilities of different location providing unbiased information to Stabilise the production, transportation process. Integration of different levels of automation to ensure data consolidation Communication (WAN) to make Hierarchical Automations system to provide asset/corporate level consolidation of the multiple production, transportation and Storage systems spread across Cities, States and Countries Applications to carryout production process optimisation, Pump optimisation, Make optimum use of the energy in the form of Gas used for the Gas Lift, Electricity used for ESP,SRP etc Integration with Scientific and Business system for Operational efficiency improvements, strategic Decision Making

Agenda of Presentations Present Oil Field and Platform Operation Practices Concept of Smart Oilfield and Platforms Smart Oilfield and Platforms – Detailed View Instrumentation Automation Communication Applications Business & Scientific System Integration Case Study – ONGC Enterprise wide SCADA

Smart Oilfield and Platforms - Instrumentations Instrumentation and devices on Well head Well head to have pressure temperature measurement as Pressure, temperatures and flows Chemical injection rates Water injection rates Downhole instrumentation All instrumentation must be low power instrument Data from Well head instrument to be consolidated in a device such as an RTU, PLC, VSD or others Device should be low powered and provide Radio communication to the central Facility Devices should be capable of implementing Control Well shutdowns based on emissions, facilities upset Dedicated devices with history retention Well Optimisation through pump, pressure, injection and/or flow control

Smart Oilfield and Platforms - Instrumentation Instrumentation at Facilities Mass flow with API corrections is the most accurate way to measure liquids AGA is the recommended standard for measuring gas Gas Chromatograph for Gas Composition measurement NOC to calculate Water cut measurement Storage tanks Level Measurement with API Corrections Group Separator Level measurement can be through Interface level transmitters Control Valves for the level and pressure control of Group Separators Suitable LACT and Gas Custody transfer meters Flare Gas Measurement through suitable flow meters Turbidity meter for solid particals measurement in water disposed – Environment / Pollution requirement Instrumentation for the Gas Compressor efficiency calculations Use of FF based instruments for diagnostic information and Asset Management applications

Smart Oilfields and Platforms - Automation Automation at well head Well head based measurement to provide remote Shut Down Access on the well head Choke control to reduce the Sludge effect in oil wells Provide Control based on Gas Lift Pressure and flow All Control are implemented through a device which Communicates through radio Automation system to provide Low B/W data Communications Automation system to support RTU data Storage and Upload in case of loss of communications Automation system to have option for configuring polling frequency as per the needs. In case of rod pump well - pump off controls In case of ESP based well ESP pump Speed / flow Control and On off Control.

Smart Oilfields and Platforms - Automation Automation at Facilities Valves control for Well test Control of Test, Group Separator Level and Pressure for Process Stabilisations AGA 3, 7 with AGA8 for Gas Measurement API based VCF for liquid measurement Artificial Lift system control for the Gas lift, Rod pump well, ESP Wells Automation system to support data Storage at each of hierarchical locations in case of loss of communication and Upload once communications is established Automation system to have option for configuring polling frequency as per the needs. Integration of existing DCS,SCADA,PLC system to enable single platform for the operation, Data Storage and Analysis. Lower cost of support Automation system to be hierarchical by architecture so that the data from different oil fields can be consolidated. Remote ESD and start of facilities

Smart Oilfields and Platforms - Communication Communication at Well head and Facilities Serial communications handled through terminal servers (IP radios are more compatible) The WAN Communications should have sufficient bandwidth at different level Communication can be Radio at on shore well heads Radio, V- sat or LEO at offshore wellhead platform Fibre optic, satellite at facility level Leased line, OFC at regional Control facility and Corporate Facility In case of Remote Control Requirement alternate communication channel / Routes should be available to the final control elements – SSV, SSSV control Network Management system is a must for a large facilities Different Subnet, Domains can be created as required. A plan must be developed

Smart Oilfields and Platforms - Applications Applications at Well head These application runs in automation system at central facility and need real time data In case of oil well (FTHP, ABP,Flow Arm Temp, Annulus and Down whole Pressures are recommended) Well 3 Phase flow estimation via Virtual Flow metering. This flow measurement reduces the need to regular well tests Active well control application reduces the slugs by controlling the choke Gas lift pressure control ensures efficient use of Gas Lift DP between Well head and Facility is direct indication of Leakages

Smart Oilfields and Platforms - Applications Applications at Well head In case of Gas wells Flow measurement with AGA3 and AGA 8 Valve switching to manage water build-up Plunger Lift Control (Turner Curve, Blow V/L etc.) for low pressure wells ESP and PCP Control for water take off Compressor Monitoring (OEM curve to Real time curve comparison) Nominations Control to ensure the consistent productions In case of CBM Wells Flow Measurement with AGA3 and AGA 8 Water level Measurement and Pump Control

Smart Oilfields and Platforms - Applications Application at Facilities Different applications are envisaged at the facilities which need real time data form the automation system. These applications are Automated well test Gas lift Optimisation Field / Pipeline Mass balance Well Monitoring System Tank Gauging System Leak Detection and Leak Location for pipelines Asset Management systems Alarm Management Abnormal Condition Monitoring

Smart Oilfields and Platforms - Applications Well test application (Onshore/ Offshore) Automatic well test application selects the well for testing by operating the heather valves Multiple well of the facilities can be scheduled for well test in sequence as desired by the operator. Each well test provides Oil, Gas and Water flow over a 24 hrs of testing along with well pressure and gas oil ratio Well test has accept/reject option for the well test data based of operators judgement Application maintains history of each well test data which can be used for analysing the well history as well as providing it to other applications The well test data is used by other application such as Production Allocation Gas Lift Optimisation Well Monitoring System ESP Optimisation

Smart Oilfields and Platforms - Applications Gas Lift Optimisations (Onshore/ Offshore) To optimise the gas used for gas lift based on best possible oil production from well This is a model based optimisation package which need input from well test to know the oil and gas flow of a particular well Lift Curves are generated by the model or can also be manually fed to the system GLO provide an output which is a reference to the flow / pressure control loop of lift gas circuit The automation system uses these reference to control the flow of lift gas in the well annulus The GLO helps in managing the Lift gas network created for different oil wells in same or adjacent oil field

Smart Oilfields and Platforms - Applications Asset /Field and Pipeline Mass Balance (Onshore/ Offshore) Asset/Field Mass balances are applied to the facilities. Imbalance is indicator of leakages This is based on Current day, Current Hour and Previous Day, Previous our flow estimations Pipeline mass balances is to identify imbalance for facilities linked through pipelines Imbalance is indicator of theft or leakage In case of Gas Pipeline Line pack calculation based on pipeline segment and is must as change in line pack can provide imbalances In case of liquid pipelines if the temperature variation across the pipeline is considerable then only change in line pack has impact on imbalance

Smart Oilfields and Platforms - Applications Sensor Readings Well Monitoring System (Onshore/ Offshore) These are Model based application which calculates Oil, Gas and Water flow from each well. These are called as Virtual flow metering They reduces the need to regular well test WMS system uses well head based measurement. The change in the differential of pressure, Temperatures is provided to well model which then provides Oil, Gas and water measurements These methods are cost effective and considerably accurate. Being model based also easy to calibrate based of latest well test These real time flow provides inputs for the Active well control, Reservoir modelling etc Models & Solver Flow Rates

Smart Oilfields and Platforms - Applications Tank Gauging System (Onshore/ Offshore) Storage Tank level measurement based on radar gauges The Tank gauging should be integral to the Automation system Tank Gauging system to have Strapping Table Calculation tool Tank Gauging system to provide Gross and Net Volumes based on the API Table 11.1.24.7.1.1 and API 11.1.54.7.1.1 for oil and oil products. VCF from these tables relates the volumes at specified temperatures to the volume at standard temperatures Facility wise inventory calculation and reporting

Smart Oilfields and Platforms - Applications Leak Detection System Performance Parameters Detection of the Leak S.No. Leak Size % of Flow Time to Detect Leak (Anywhere in Pipeline) 1 Full Bore Rupture 100 1 min 2 Large Leak 50 2 min 3 Medium Leak 25 4 min 4 Small to Medium Leak 10 10 min 5 Small Leak 20 min 6 Very Small Leak 100 min Estimation of the Leak Location Estimation of Leak Locations 60 KM 2 to 50 30 KM > 50 20 KM Leak Detection and Leak Location system (Onshore / Offshore) Pressure Measurement are required across the pipeline at a specified distances to ensure the level of accuracy Leak Detection Can be implemented via Pressure Surge Pressure Wave Flow Mass/Volume Balance

Smart Oilfields and Platforms - Applications Asset Management System Use of FF, Hart and Profibus based instrumentation and automation system provide Diagnostic Information along with the Real time information's These diagnostic information is used to predict the possibilities of failure of the critical control equipments The AMS system provides the mean to identify the such possibilities of failure and use them to carry out the maintenance activity in advance. The diagnostic information's triggers the CMMS system and CMMS provide Work order for the necessary actions The Asset management module can also be used for rotating equipment and also some process equipment monitoring through customisations Planned and on time maintenances reduces the downtime and support the production planning CEAG I/O P5001 0 ... 150 bar

Smart Oilfields and Platforms – Integration Integration with ERP System (SAP) Majority of the customers used the SAP as ERP system in Oil and Gas Industries The Automation system integration with the SAP is must to ensure the error free production, Sale numbers reporting on day to day basis Automation system can feed the data to different modules of SAP Production Numbers in PPPI modules Custody Transfer Numbers to SD Modules Diagnostic and Maintenance Data to PM modules Integration with Scientific Systems Reservoir modelling and analysis systems Drilling system for LWD/MWD Integration system provides the data validation to ensure correct numbers are sent to integrated systems

Agenda of Presentations Present Oil Field and Platform Operation Practices Concept of Smart Oilfield and Platforms Smart Oilfield and Platforms – Detailed View Instrumentation Automation Communication Applications Business & Scientific System Integration Case Study – ONGC Enterprise wide SCADA

The Project Envisaged Enterprise Wide SCADA for all Production and Drilling Facility of ONGC Spread across India and in Arabian Sea. The project is envisaged by core design and engineering team of ONGC under the initiative of Chairman of ONGC Limited Main reason for ONGC to think about such LARGE architecture Efficient Real time Monitoring of the Production and Drilling Parameters across all the assets in India Remote control of the production well in case of Offshore platform Facilitate offline analysis of the Valuable/ High Producing Wells through third party E&P Applications. Provide summarised information to the management for effective decision making Total Facelift in the day to day operation of ONGC Production and Drilling facility to improve the efficiency

The Scope of Supply and Work Supply of Three Tier SCADA Architecture as Production SCADA and Drilling SCADA spread across 19 Assets in India. The Production SCADA is ABB SCADAvantage and Drilling SCADA is NOV solution RTU with FF based Instrument for the Production installation to enable data acquisition and asset management. Supply of 16 Data Centres including the corporate data centre across India to enable efficient operation of respective Assets. UPS for all the 250 plus tier 1 control room of production and drilling SCADA along with FCBC for 85 no of remote RTU with solar chargers. SAP, Epinet, VRC- Integrations of Real-time and History Data. Disaster Recovery Solution for the corporate data centre. Scope of Work Erections and Commissioning of above scope and warranty for one year AMC of 6 years after warranty

Unique Features of the SCADA Project Single Largest Instrumentation- Automation – IT Solution project finalised in India – 95 musd Largest three tier network of near real time process data monitoring. The no of HMI Station in a single largest Network - 1300 Plus HMI Stations and 600 Plus Servers Largest Project in term of the FF based Instrumentations and automation solution – 7500 FF instrument and 850 FFH1 segments First Ever project with FF and Hart based RTU and Asset Management. Largest project in terms of Field Instrumentation scope of supply Largest Oil and Gas producing wells connected to the SCADA system – 18000 Wells Single largest contract to build 179 Control rooms, 16 Data centres and 75 Mobile Control rooms

ONGC SCADAvantage System Architecture Tier 3 in Delhi with backup in Mumbai 13 x Tier 2 Locations 163 x Tier 1 Onshore SCADA Locations 8 x Tier 1 Offshore SCADA Locations 278 x RTU Locations