yokogawa electric corporation bmd-d0008 copyright © yokogawa electric corporation oct 29, 2004...

Yokogawa Electric Corporation

BMD-D0008Copyright © Yokogawa Electric CorporationOct 29, 2004

Yokogawa Upstream SolutionsOct 29, 2004

Yokogawa Upstream Industry SolutionsPage.2


Upstream

Downstream

Various upstream applications

Offshore

Onshore

Pipeline



Customer Challenges

Do you need to reduce investment?– Integration of commercial and industrial systems– Appropriate network fit for purpose

Our Solutions• Control system with proven open architecture• Fieldbus technology reduces wiring and transmitters• Robust and flexible communication between SCADA and

controller

Does high operation cost trouble you?– More effective production, more accurate metering– Avoid failure or accidents in operation

Our Solutions• Remote operation and remote maintenance • Digital sensing, multi variable sensing• Emergency shutdown system• Integrated safety and control system• PRM Asset Management System



Upstream Market Strategy

Oil & Gas Market Demands More Competition– Move forward to improve upstream rather than downstream.

Increased Demands For More Efficient Operation– Move forward to secured, autonomous operation.

Our commitment is to help you succeed in meeting market demands““ ””

► Pipeline ► Onshore Production ► Offshore Installation



► Various Field Instruments

► Remote Diagnosis

► Fail-over Communication

► Network Flexibility

► Event Driven

Communication

► Gas Flow Measurement

► Gas Analysis System

► Security

► Flow Calculation

► Composition Analysis

► Compressor Control

► Monitoring the Metering Station

► Blocked Impulse Line Detection

Pipeline

Application Proof

► Sakhalin II

* Click ► to see more details

► For Pipeline




► Remote Diagnosis

► Fail-over Communication

► Network Flexibility


► Integrated Safety System

► Gas Lift Optimization (Injection Control)

– Thermal Recovery


► Pumping Unit Maintenance

Onshore Production

Application Proof

► Wellhead for Shell Nigeria

► Wellhead for PDO

► Enraf Tank Gauge Application


► For Onshore Production



– Control System



► Integrated Safety System

– SCADA – Safety Operation

Offshore Installation

► Gas Lift Optimization (Injection Control)

– Thermal Recovery


– Gas Separation

– Offshore Platform Level Control

– Steam Generation

Application Proof

► FPSO for Vanguard SPC

► FPSO

► Subsea Equipment


► For Offshore Installation



Applications Adopted In Upstream Industry



Flow Calculation

Support AGA Calculation– Orifice plate (Flange taps or Pipe taps) metering of natural gas : AGA3, AGA8– Turbine metering of natural gas : AGA7, AGA8– Historian : 35 days daily average data

Pressure and DifferentialPressure for AGA3

Full digital calculation

Gas ChromatographYokogawa GC1000

Gas CompositionFor AGA8

FF-H1(Redundant)

Modbus

Differential Pressure TransmitterYokogawa EJX

Control System

► For Pipeline



Composition Analysis

Robust– FM approved (Class1 Division 1)– Drip proof, Dust proof design (NEMA3R IP52)– Wide operation condition (-10 to 50 Deg)

Unique and Reliability– Accurate and low air consumption air bath oven – Reliable and easy maintenance sample valves– Stable carrier gas flow because of the regulator in the oven

High Sensitivity TCD and Wide Range Application Capability– Can cover FID application– PIONA (ASTM D5134) – Simdis (ASTM D3710)

Upstream composition analysis requires the suitable gas chromatograph for its location.

► For Pipeline





Composition Analysis - Example

GC1000

Component Range

N2 0-10%

CO2 0-10%

methane 0-100%

ethane 0-10%

propane 0-5%

butane 0-2%

isobutane 0-2%

pentane 0-1%

isopentane 0-1%

neopentane 0-1%

C6+ 0-1%

► For Pipeline



Compressor Control

For Efficient Compressor Control– Control compressor number according to the gas or oil demands.– Control the speed by throttling, diverting the outflow.

For Stable Supply– Control gas supply from the underground tank to meet the

demands in the wintertime.– Control gas storage to store surplus gas to underground tank in the

summertime.

Control SystemSCADA

► For Pipeline



Monitoring the Metering Station

Metering StationMetering Station

Metering StationMetering Station

SCADA Controller as a Remote Monitoring unit

Recorder

Integrated monitoring of quite a few metering station in the geographically distributed area.

– Distributed metering station in every 10 miles– Slow communication environment in the hazard area– Recording the data of unmanned station.

Differential pressure transmitter

► For Pipeline



Blocked Impulse Line Detection

More than 30% of trouble related with Orifice flow meter is caused by the blocked impulse legs.

– The blocked impulse lines slows down the transmitter’s response time.– The blocked impulse lines cause the change of the fluctuation signals.– The blocked impulse lines can be detected by watching the fluctuation.

Impulse lines flow

Online Diagnosis for Impulse Line Blocking– Accurate Diagnosis is completed by comparing

the present state with the reference state.– Efficient Diagnosis helps saving maintenance

costs providing diagnostic functions through analyzing the statistical values of the fluctuation.

PL

PH

For Accuracy and Safety Measurement

► For Pipeline



Gas Lift Optimization (Injection Control)

Remote Diagnose

– Monitor the injection pressure from remote site– Change the FF transmitter parameter from remote site– Optimize the injection pressure from remote site

FI TI

PI

Oil & Gas out

High Pressure Gas in

InjectionPressure

Optimization

Metering Flow Calculation

PI

FI

Remote Diagnosis

Production Sand

Control SystemDifferential pressure transmitter





Pumping Unit Maintenance

Maintenance of the Mechanical Parts– Preventive maintenance – Emergency notice– Analyze the breakdown

Avoid the Pump Damage– Monitor the motor speed and the current– Control motor speed– Stop the pump in emergency

Control SystemFIF Monitoring Package




Various Field Instruments

For Tank Level Control

For Orifice Pipeline

Different pressure andpressure transmitter

Coriolis Meter

Vortex Flow Meter

Gas Lift

Ultrasonic Flow Meter

Various Field Instruments for Various Applications► For Pipeline





Plant Resource Manager (PRM)

Reduction of maintenance cost contributes further reduction of TCO.– Diagnostic information extends maintenance cycle.– Computerizing maintenance data and operations

improves efficiency of maintenance management.

PRM supports unmanned and/or remote operation. (e.g. Off-shore application)– Various diagnostic information enables remote

diagnosis of field devices.– PRM supports maintenance work schedule settings.

PRM realizes a total asset management system.– Vertical Integration from Sensor Level to ERP can be

offered.



Remote Diagnosis

The multiple and distributed pipeline devices are managed from remote

– Calibration management– Alarm and status notification– Loop diagnostics– Preventive maintenance

Asset Management System

Diagnosis Data• Total cycle count of stem• Total travel distance of stem• Total open / close time

Fieldbus Alert•High / Low alarm•Sensor failure•Cycle count exceeds limit

Ethernet

FF-H1

Cellular / PDAMail server

Alarm notification via e-mail

► For Pipeline




Upstream network is not reliable – The communication is easily affected by the weather or other

environment.– The network device has low band– The network devices are sometimes not good quality.

Fail-Over Communication

The data is never lost– The precious data is stored in the controller.– Data is sent to SCADA when the communication recovers.– SCADA system shows them as sequential data

However

► For Pipeline




Communication system of upstream application have wide variety.– Region’s infrastructure– Companies infrastructure– Commodity network

GSM

Microwave Radio

Satellite

Wireless LAN

Internet / Intranet

Public telephone line

Network Flexibility

The data is sent via any network

However

► For Pipeline




Event Driven Communication

Event driven communication benefits:– No event, no communication– Low bandwidth communication lines can be used– Tune communication to requirements and availability of bandwidth

Four different types of operation:– Digital:

• No event, no communication at all times• No event, yet every fixed period of time data transmitted to FAST/TOOLS

SCADA

– Analog:• Data changes within bandwidth, no update at all times• Data changes within bandwidth, yet every fixed period of time data

transmitted to FAST/TOOLS SCADA

► For Pipeline



Gas Flow Measurement

Requirements for Application– High Accuracy under actual application conditions

• Temperature change : -10 to 50 ℃• Static Pressure change: 0 to 350kgf/cm2

Solution– DP Harp EJA130A, high static differential pressure

transmitter

Static Pressure and Temp. Effect (Zero Error)

► For Pipeline

EJA EJX



Gas Analysis System

Unique and Reliable Hardware– Accurate and low air consumption air bath oven – Reliable and easy maintenance sample valves– Stable carrier gas flow because of the regulator in the oven– Low TCO because of highly reliable hardware

High Sensitivity TCD – Can cover FID application– Save utility gases and easy maintenance

Wide Range Application Capability– PIONA (ASTM D5134) – Simdis(ASTM D3710)

Process Gaschromatograph GC1000 has stable and wide range temperature oven , highly sensitivity detectors and high reliable valves.

► For Pipeline





Security

Necessity of Security Management of Pipeline Stations

– Threats• Intruders• Robbery and burglary• Accidents/Emergency• Fire• Natural disasters

“Surveillance Camera” is our Solution– Video data monitoring / recording– Alarming / Paging– Camera control to preset positions by intruder detection

• Microwave sensor, Infrared sensor• Electric field/electromagnetic field sensor• Taut wire sensor, Trap sensor• Mercury switch sensor/ Vibration sensor• Piezoelectric sensor• Video sensor, image data processing

► For Pipeline



Integrated Safety System

Monitoring and operation of control and safety system are integrated with FAST / TOOLS

Prosafe-PLCSIL 1-3

Prosafe-SLSSIL 3-4

Safety System

CS3000

Different Pressure & Pressure TransmitterSIL2

Stardom

Control System





Case Studies



Success Story: FPSO for Vanguard SPC

Customer Challenges– Several tasks in parallel during detailed engineering. – Modification without interrupting the production.

Customer: TotalFinaElf Project : GIRASSOL FPSO Completion: Dec., 2001Application: FPSO

Customer: TotalFinaElf Project : GIRASSOL FPSO Completion: Dec., 2001Application: FPSO

The ability to perform modifications on-line is an essential factor in ensuring uninterrupted production.

Results– With Yokogawa’s intelligent system architecture, modifications was carried out online and single

modifications downloaded without stopping production.

System Configuration– DCS: CENTUM CS– Vortex Flow Meter: YEWFLO




Case Study: Offshore Platform

Customer Challenges– Complete Yokogawa’s solution covering from procurement to lifetime

maintenance– The integration of safety shutdown system and control system

Application: FPSOApplication: FPSO

Complete Yokogawa’s solution to FPSO using FOUNDATION Fieldbus technology and integration of control and safety system.

Results– Yokogawa offers complete solution covering from procurement to

lifetime maintenance – Yokogawa offers FOUNDATAION Fieldbus devices.– Yokogawa integrates the emergency shutdown system and control

system with SCADA.

System Configuration– SCADA: FAST/TOOLS

Controller: Stardom FCN (Redundant System)Emergency Shutdown System: Prosafe100Mbps Redundant Fiber Optics Network



Application Detail

System Capability– Yokogawa provided the integrated system of control and

emergency shutdown system.– Yokogawa provided the FOUNDATAION Fieldbus connection.– The Yokogawa solutions provide process, facilities and

safety control for the FPSO

Project Capability– Total system supply enables the customer ease of

procurement, engineering and maintenance.




Case Study: Subsea Equipment

Customer Challenges– FF technology in the field of subsea as the “Field of Future”

Application: Subsea MeteringApplication: Subsea Metering

The world’s first sub sea Foundation Fieldbus project

Results– This system is becoming the showcase for the

customer.

System Configuration– Controller: Stardom FCJ– Differential pressure and pressure transmitters: EJA



Application Detail

The worlds first sub sea Foundation Fieldbus project – Robust controller and FF device combination guides the

customer to the next generation advanced metering solutions.

Yokogawa’s products are highly suitable to the extreme location: – Since the oil & gas companies are going to explore more and

more extreme locations, facilities like control, metering and safety are also pushed into these extreme locations and the more robust products are required.

– Application reusability is required.

The formulas based on years of experience are encapsulated and ported from a PC platform into the Yokogawa’s controller. – This encapsulated formulas can be re-used as a library without

engineering.




Success Story: Wellhead for Shell Nigeria

Customer Challenges– Open architecture system incorporating FOUNDATION Fieldbus– Remote monitoring and control on a corporate LAN– New technology such as notifying an alarm via e-mail

For the Shell Petroleum Development Company of Nigeria (SPDC), STARDOM is playing a significant role in optimizing their oil production system and accounts for more than 50 percent of the country's oil and gas production.

Results– Open System Architecture, which incorporates FOUNDATIONTM Fieldbus, Java

technology and a Web-based operation interface. – Field is controlled from a remote location such as a PC on a corporate LAN,

incorporation of the FOUNDATION fieldbus interface.– System status and other information are notified to operator by e-mail.

System Configuration– Controller: Stardom FCN– SCADA: Web-based SCADA VDS

Customer: Shell Petroleum Development Company of Nigeria (SPDC) Application: Gas Lift Optimization

Customer: Shell Petroleum Development Company of Nigeria (SPDC) Application: Gas Lift Optimization



Field DevicesCustomized Function

Blocks

Alert e-mail Notification

E-mail ServerField Network

ALERT

FCN

Remote Operation & Monitoring

Alert e-mail Notification

On Web Browser

Operation & Monitoring

Office

Remote 　　　　　　　　 Operation &

MonitoringOn Web Browser

Headquarter

Site

STARDOM is fully compliant with Thin Client Technology

So, No special software is required for remote operation and monitoring.

On Web Browser

Web Based SCADA /

VDSData Acquisition & Saving

• Remote Control (unmanned operation)• e-Mail notification • Java

System Configuration in SPDC Nigeria



Testimonial

A process automation system provides operational flexibility, which also serves as an enabler for minimum intervention strategies, remote diagnostics capabilities, unmanned operations and a seamless integration with management information systems. The open technology allows SPDC to customize their process automation system without fearing integration problems and premature obsolescence, providing a scalable system to nurture the migration into an integrated oil/gas operation within SPDC. It is our firm belief that the systems architecture espoused is representative of best practices across the industry, taking into account enabling technologies using commodity type components in a world of competitive opportunities. Thus the benefits, attraction and appeal of applying open system architecture within SPDC are plainly evident and will result in the breakthrough performance stan

dards we aspire to achieve.

Mr. Dick WismeijerCorp. Head Instrumentation/ControlShell Petroleum Development Co.

A process automation system provides operational flexibility, which also serves as an enabler for minimum intervention strategies, remote diagnostics capabilities, unmanned operations and a seamless integration with management information systems. The open technology allows SPDC to customize their process automation system without fearing integration problems and premature obsolescence, providing a scalable system to nurture the migration into an integrated oil/gas operation within SPDC. It is our firm belief that the systems architecture espoused is representative of best practices across the industry, taking into account enabling technologies using commodity type components in a world of competitive opportunities. Thus the benefits, attraction and appeal of applying open system architecture within SPDC are plainly evident and will result in the breakthrough performance stan

dards we aspire to achieve.

Mr. Dick WismeijerCorp. Head Instrumentation/ControlShell Petroleum Development Co.

””

““► For Onshore Production



Case Study: Wellhead for PDO

Customer Challenges– Fit in to existing communication infrastructure– Acquisition enough information for FF-H1 device maintenance using SCADA from miles and

miles away– System integration – Safety, Controller and other devices on the same network

Customer: Petroleum Development Oman (PDO) Project: Harweel oilfield development project Customer: Petroleum Development Oman (PDO) Project: Harweel oilfield development project

Yokogawa’s total solution provides the integrated information from safety system, control system and field devices to the operator via existing communication infrastructure.

Results– Data acquisition via redundant optical fiber network which is the existing communication infrastructure.– With FAST/TOOLS(SCADA), the information from Prosafe-PLC(Safety System) and STARDOM FCN(Control

System) is integrated.– Information for FF-H1 device maintenance is managed with PRM

System Configuration– Controller as RTU: Stardom FCN– HMI and SCADA: FAST/TOOLS– Safety System: Prosafe-PLC– Asset Management: PRM



PDO Head OfficePDO Head Office

Overview

Wellhead Remote Manifold Harweel Station

New Field

BV Station

Expansion of existing station

Bibra

Corporation Network

PRM



ESD (Emergency Shudown System)and F&G system (Fire and Gas Safety System)

ProSafe-PLC

Field instruments

Asset ManagementPRM

Interface to existing EMS via OPC

Yokogawa Solution for PDO

SCADA integrating control system and safety system

FAST/TOOLS

Control SystemStardom FCN

•Fiber Optic connection to Harweel station

•Connection to PDO LAN through Firewall and FO converter

•Redundant Control & Safety networks

•Fiber Optic connection to Harweel station

•Connection to PDO LAN through Firewall and FO converter

•Redundant Control & Safety networks



HMI Screen and The Actual Control Nest



Testimonial

STARDOM is a rugged control solution that can be used without cooling, provides a suite of remote capabilities like predictive maintenance and is simple to maintain.

By using STARDOM, we are able to save costs in maintenance and operation by minimizing the visits to wellheads, thus reducing HSE exposure for our operations staff.

Shihab Al-BarwaniEngineering Manager

Petroleum Development Oman

STARDOM is a rugged control solution that can be used without cooling, provides a suite of remote capabilities like predictive maintenance and is simple to maintain.

By using STARDOM, we are able to save costs in maintenance and operation by minimizing the visits to wellheads, thus reducing HSE exposure for our operations staff.

Shihab Al-BarwaniEngineering Manager

Petroleum Development Oman ””

““► For Onshore Production



Case Study: Pipeline in Sakhalin

Customer Challenges– Remote operating a pipeline under extreme ambient conditions– Avoid travel in these conditions as much as possible– Requires full remote operability of the control systems and high reliability &

availability

Results– Full scale FOUNDATAION Fieldbus technology– Integrated HMI environment with PCS system; Same Look and Feel– Set up local support base in Sakhalin island for training, commissioning and

maintenance work, involving Russian resources which will contribute to both business and the community.

Customer: Chiyotec Limited.Project: Sakhalin IILocation: Sakhalin Island, RussiaThe onshore oil and gas pipelines will run from Piltun in the north of Sakhalin Island via the Onshore Processing Facility. The two pipeline systems will each cover a distance of over 800 km.

Customer: Chiyotec Limited.Project: Sakhalin IILocation: Sakhalin Island, RussiaThe onshore oil and gas pipelines will run from Piltun in the north of Sakhalin Island via the Onshore Processing Facility. The two pipeline systems will each cover a distance of over 800 km.

SAKHALIN ENERGY awarded the big order to Yokogawa with the combination of STARDOM and Fast/Tools



Sakhalin II Location

OnshoreStabilization

Facility

Oil & Gas Export

TerminalGas Pipeline

Oil Pipeline

Russia

Japan

Sakhalin

Piltun

Annual Production Capacity of 9.6 million tons

Location: Sakhalin Island, RussiaThe onshore oil and gas pipelines will run from Piltun in the north of Sakhalin Island via the Onshore Processing Facility. The two pipeline systems will each cover a distance of over 800 km.



Sakhalin II System Configuration

POMSserver

EWS 1LDS

communicationbackbone

GDTRTU(1)

Local PCS systems- LUN-A - PA-B- BS#2 - LNG- OPF - PA-A

RTUtype 1(68)

RTUtype 2(39)

RTUtype4/5 (2)

Dual screenHIS

ExaOPC

FCS

Integrated HMI environment

EWS 2

PA-AOS

ExaOPC

FCS

printer

SEOCC

OPF

PA-ABlock valve stations

*

* *

Dual screenHIS

HMIEWS

FCS Dual screenOS

LNG

POMS scope

Redundant hardware

Simplex connection

Redundant connection

*

Out of POMS scope

BCV*

communicationbackbone

*

*

*

*

► For Pipeline



Case Study: Enraf Tank Gauge Application

Customer Challenges– The customer’s current communication & interface

product portfolio between tank gauging instruments and control room didn’t gather to control and open automation needs and needed completion

ENRAF has chosen STARDOM as the platform for open tank gauging systems for a number of typical applications within tank terminal automation and inventory management.

WW Headquarters: Delft - NL, subsidiary of Delft InstrumentsCurrent position: WW market leader in tank storage managementWorldwide: 11 regional offices, present in 60+ countriesApplication: Inventory Management, Communication Module

WW Headquarters: Delft - NL, subsidiary of Delft InstrumentsCurrent position: WW market leader in tank storage managementWorldwide: 11 regional offices, present in 60+ countriesApplication: Inventory Management, Communication Module

ResultsThe seamless combination of TCP/IP based open networks, various field networks such as FF-H1 and Modbus and OPC functionality of STARDOM meets the new market demandsIt enabled Enraf to realize flexible and advanced tank terminal automation solutions with major improvements on functionality and performance as well as connectivity and integration Back




First to MarketFirst to Market

Reduce Investmentwith combination of industrial and commercial products and system, more open and flexible system meets your desired application.

Best Quality, Best Productivity, Best ROI

Yokogawa provides the best solutions and knowledge for your upstream field, and Yokogawa can make you first to market.

Improve safetyby good combination of safety and control system through lifecycle operation make your system more safety than ever imagined.

Reduce Operational Costwith integration from MES to field instruments, operation efficiency will be dramatically improved.

Benefits as experienced by Yokogawa’s Upstream customers:

“Bottom line of upstream operation is safety. With combination of Yokogawa’s safety and control system, I can run my upstream field more relaxed and trusted.”

“Environment of upstream field is extreme and infrastructure is limited. Integrated system, which adopt to the existing infrastructure, fits our requirements.”

“The biggest benefit of Yokogawa, that I have never experienced, is the lifecycle service to run to the hazard upstream filed.”



Thank you for your attention.

Commitment means building the future to last.

yokogawa electric corporation bmd-d0008 copyright © yokogawa electric corporation oct 29, 2004...

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