CC BY
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Section 13. Technical sciences
Tulyaganov Shuhrat Dilshatovich, Senior Researcher of the development of oil and gas fields in the Tashkent State Technical University named after А. R. Beruni. (Uzbekistan)
E-mail: shtulyaganov@mail.ru. Nesterov Igor Valentinovich, Chief Engineer of LLC «ASU-Engineering» (Uzbekistan).
E-mail: asueng@mail.ru
Modern automated control systems in the oil and gas industry example on installation of preliminary gas preparation Kumli
Abstract: The relevance of automation is due to several reasons: the main — and increase gas production system complexity, increase reliability requirements of the systems, the economic effect, stricter environmental requirements. One of the main resource — the continuous development of information technology, the emergence of new ways to solve various problems, new tools.
Keywords: automation, process control, installation of gas, the control parameters, measurement
Introduction
The main goal of modern automation systems is to minimize human involvement in the management process. Intelligent process control — the main trend in the development of automation.
Lets consider automated process control systems, typical for installation of preliminary gas preparation of Kumli.
Condensate field «Kumli» administratively located in the territory of Karakul district of Bukhara region of Uzbekistan.
Installation of preliminary gas preparation «Kumli» designed for natural gas purification from dropping liquid and solids.
Productivity Installation of preliminary gas preparation «Kumli» Gas 2.35*109 m3 per year.
The raw material for Installation of preliminary gas preparation «Kumli» is the production of gas wells field Chegarakum, Kushimcha, Tailak, Kumli containing, besides the gas phase, liquid hydrocarbons and formation water. In the flow of production wells also contained mechanical impurities.
Natural crude fuel gas is a multicomponent mixture and a small amount hydrocarbons
Average composition of the gas entering the UPPG «Kumli» is shown in Table 1.
Table 1. - Composition and parameters of the gas entering the UPPG «Kumli»
Indicator name Unit. Measurement Value
1. Component
СЦ % 91,39
C2H6 % 2,65
cX % 0,45
iCX % 0,08
nCX0 % 0,08
CX+ % 0,72
N2 % 0,68
CO2 % 2,19
H2S2 % 1,27
h2 о % 0,49
Total 100
2. Molecular weight of gas kg/kmol 18,245
3. Density at 20 °C and 760 mm Hg kg/m3 0,758067
The main part
Automated process control system installation preliminary gas «Kumli» is designed to monitor the progress of conducting the process in order to maintain the specified
parameters of working environment, stable and troublefree operation of the plant, as well as to monitor key parameters when starting the installation and displays it on the operating mode, when stop the installation, its warm-
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Modern automated control systems in the oil and gas industry example on installation of preliminary gas preparation Kumli
ing and purging. For this purpose, devices and systems are provided for the measurement and recording of pressure, temperature, differential pressure, flow and level among the apparatuses and communications setup to automatically maintain the specified environment settings for automatic protection equipment installation from exceeding the specified parameters [1, 176].
Automated process control system provides the following monitoring and control functions:
1) control over the installation processes (primary and secondary nodes), the measurement of process parameters and the information obtained about the state of technological objects on duty operational and technical personnel;
2) automatic control — is the stabilization of the individual (local) process parameters, ensuring the stability of the technological process and the implementation of the control functions being to stabilize the basic parameters;
3) Remote control — is the management of operational and technical staff of the regulatory, shut-off valves and process equipment;
4) software and logic control equipment installation;
5) emergency automatic protection and blocking;
6) alarm status objects — fixing the technological parameter of the specified limits, the alarm shut-off valves and the state of technological equipment, signaling perform emergency protection and locks;
7) record, the accumulation and storage of measured current values of the process parameters on the magnetic storage computing means in real time with the presentation ofthe subsequent recorded values as a historical trend.
8) an efficient and reliable process control installations preliminary gas and auxiliary installations minimiz-
ing operator involvement in the process and thus release staff from performing minor tasks and handmade.
Mode of operation of the automation object — a continuous, non-stop to the scheduled preventive (every six months) and forced the repair work.
Technological part of the installation preliminary gas «Kumli» includes:
— Installation of a gas treatment plant;
— Technological platform;
— Gas control;
— Site host. gas meters;
— Drain the condensate tank E-1;
— Ground flare separators and drain tanks;
— The capacity of production and rainwater;
— Pumping condensate;
— Pumping station of disposal of industrial waste;
— Pumping station fire-fighting purposes;
— Warehouse condensate V = 500 m3.
SCADA system implements a set of information and support functions [2, 407-411].
Information functions on Installation of preliminary gas preparation are: control and measurement of process parameters; trigger lock control and protection; passing control commands to the controller; control of correctness of the choice of the control object; alarm parameters deviations from the established boundaries; alarm system disorders of equipment; manual data entry; formation and delivery of data to operational staff in the protocol format of messages regime sheets and reports of emergencies; calculation of indirect variables; collecting and storing data [3, 79-89].
Figure 1. shows a block diagram complex of technical means
Figure 1. Block diagram of the control system of the technical means installation of preliminary gas preparation Kumli
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Control functions:
— Issue of control actions from the PC to shutoff valves, fans, pumps and other process equipment, by changing the value of bits of memory in PC-controller series Beckhoff CX5020;
— Issue ofjobs and the controller mode of the automatic process control in local mode or cascade control, implemented on a PC-based controller Beckhoff;
— Changing the operating mode of the object in
the real time by selecting an appropriate control algorithm.
Auxiliary functions:
— Self-diagnosis of the complex hardware and software;
— Help screen the operator;
— Time correction of system users;
— Registration of the person performing the management of the facility.
Fig.2. Scheme gas treatment unit Installation of preliminary gas preparation «Kumli
Complex technical means of automated process control system has the following structure:
- The lower level is a actuators, instrumentation and automation, instrument cabinet is designed to power the sensors and instrumentation A.
- Medium level consists of a controller cabinet SK-Kum. SK-Kum is designed to control and direct control equipment Installation of preliminary gas preparation. The cabinet SK-Kum is PC-controller of the company Beckhoff (Germany) with additional equipment and operator panel for reserve management.
- The upper level for the implementation of human-machine interface (HMI) with automated control system Installation of preliminary gas preparation.
The upper level consists of a server cabinet, communications and networking equipment consisting of:
• 2 redundant servers automatically collect, mathematical data processing, process control, maintenance
of archives. To improve the reliability of redundant pair of servers used to working in sync to maintain a virtual server. In case of failure or the physical destruction of one of the nodes of the system or its components, the system remains in working condition and continues to work without any interruption;
• Operator Workstation are intended to provide technological information in the form of survey personnel, trends, mimics and remote process control. Communication between the operator stations with the server is done over the LAN Ethernet;
• Engineering station — is designed for configuration and diagnostics software and hardware of the control system (controllers, etc.);
• Redundant Ethernet network combines a redundant pair of servers c controllers systems.
Ethernet Network brings together a redundant pair of servers, workstations.
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Modern automated control systems in the oil and gas industry example on installation of preliminary gas preparation Kumli
Figure 3. Scheme preparation of condensation on
The average level of the control system
SK-Kum are based on specialized industrial PC controllers BECKHOFF (Germany) is located in the closet complete automation. PC controllers BECKHOFF-means is highly proven on the world market.
PC-controller BECKHOFF a process controller, focused on large-scale application in process control and automation facilities with high demands on reliability of operation, including the locking system and emergency automatic protection (ESD).
As the system bus is selected EtherCAT, which supports almost any topology: linear, tree, star. Bus or linear structure used in industrial networks, and is available on the Ethernet. Especially practical for connecting devices in the system is a combination of linear connections and branches. The necessary interfaces are available on the controllers, so additional switches are not needed. Of course, you can use the Ethernet topology classic «star» with the switches.
EtherCAT system provides a new level of performance. The protocol is carried out solely by the use of the chip module FMMU and direct access to the network card master device. This ensures independence from the runtime protocol stack, CPU performance and the software used. Poll 1000 input-output devices produced in just 30 ms, including a series of read and write module. One Ethernet-frame can be up to 1486 bytes sodezh-rat information — this is equivalent to the transfer of nearly 12,000 digital I/O signals. Transfer this amount of data takes only 30 ms.
To ensure reliability, longer service life and reducing the time of the repair work at the delivery system
Installation of preliminary gas preparation «Kumli»
provides spare parts for three years of operation. In the process control system installed «Kumli» provides hardware reserve I/O modules installed analog and digital signals — 20% and 30% analog discrete.
The design of the equipment management system provides security during routine maintenance:
• without removing the power supply voltage — cleaning and wiping equipment enclosures;
• with stress relief (insulation resistance measurement, the replacement of electronic components).
Protective earthing of equipment, metal and shielding cable sheath meets the SAE.
Equipment under voltage is provided with an indication of having power switching devices and circuit protection power.
Lighting levels, noise and vibrations generated by the control system’s hardware, not exceed health standards in the location of the operating personnel.
Conclusion
To solve this problem the specialists of LLC»ASU-En-geeniring» and Tashkent State Technical University named A. R. Beruniy been developed and implemented complex algorithms ensure the establishment ofsystems ofautomation control type — automatic control of technological objects.
Intellectualized technology has a number of significant advantages: requirements for the number of operating personnel reduced to a minimum, reducing the cost of the technical system, the informativeness of the equipment and process technology reaches its maximum, maximum economy of power resources by automatic control parameter optimization operation of equipment and technology as uniform technological complex.
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References:
1. Mankveyn V. T. Frolov S. V., Shechtman M. B. Application SCADA-systems for process automation: manual. M. Tombov: Machinery, -2000. - 176 p.
2. Nesterov I. B., Tulyaganov Sh. D., Nazarov А. U. Innovative automated control systems for excavition oil and gas, their role in resourcesaving//Eighth world conference on intelligent systems for industrial automation. November 25-27, Tashkent., 2014. P. 407-411.
3. Nazarov А. U., Nesterov I. V., Tulyaganov Sh. D., Nazarov U. S. The strategy of development of modern automated control systems in problems of reconstruction and modernization processes oil and gas industry. Uzbek Journal of Oil and Gas. Special edition. May 12-14 Tashkent., 2015. P. 79-89.
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