1. Smart Oilfield and Platforms Case Study – ONGC Enterprise wide SCADA

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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.

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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

20. 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 and API 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

21. 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

22. 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
P bar

23. 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

24. 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

25. 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

26. 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

27. 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 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 – Wells
Single largest contract to build 179 Control rooms, 16 Data centres and 75 Mobile Control rooms

28. 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