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The ABB Solution for the E&P Industry

The ABB Solution for the E&P Industry. Organization:- ONGC Limited, India Project :- Enterprise Wide SCADA System for the Production and Drilling Facilities. BU (Oil and Gas), ABB limited, Bangalore. Intro – The Organization ONGC Ltd.

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The ABB Solution for the E&P Industry

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  1. The ABB Solution for the E&P Industry Organization:- ONGC Limited, IndiaProject :-Enterprise Wide SCADA System for the Production and Drilling Facilities BU (Oil and Gas),ABB limited, Bangalore

  2. Intro – The Organization ONGC Ltd. • The Organisation ONGC Limited – Oil and Natural Gas Corporations limited is a Navaratna Public Sector Unit. A Company floated by Government of India • Listed in BSE (Bombay Stock Exchange) and has market capitalisations of over 40 billion USD. Single largest company in BSE. • It produces 27 MMT Crude Oil and 26 bcm of Natural Gas. • The company has a profit of 2 busd and has Capital Expenditure over 4 busd every year. • Going aggressively around the world to meet India's energy requirement through a subsidiary called OVL (ONGC Videsh limited). • ONGC also floated a joint venture with LN Mittal Steel Co (Single largest UK based steel baron) for the E&P business and has acquired block in Africa • Primary business is E&P and now venturing into the Refining and Petrochemicals sectors. • The present E&P Business if spread across the length and breadth of India and SCADA is envisaged at present for Indian installations

  3. 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

  4. Competition Faced • Totally 17 No of bidders took the tender, some of the major are Honeywell India, Yokogawa, Emerson, EIL, L&T, etc. • Only ABB and Honeywell could submit the offer due to short time and large volumes of the project. • With in three week of submission the Honeywell bid was technically rejected on account of qualification criteria in terms of • No Proven track record of Multi tier SCADA Architecture • Non Field bus compliant RTU without Asset Management • Capability to execute the project • Only ABB Price bid is opened after technical evaluation • We went for a hard negotiations for 4 months period and finally won the order above 10% of ONGC budget. • ABB two year plus pre-bid selling of the SCADA and Fieldbus compliant RTU has helped to build the confidence in ONGC and bag such a big order. • With this order ABB India is a Undisputed leader in upstream oil and gas solution in India.

  5. The Scope of Supply and Work • Scope of Supply • Supply of Three Tier SCADA Architecture as Production SCADA and Drilling SCADA spread across 19 Assets/252 Locations in India. The Production SCADA is ABB SCADA Vision and Drilling SCADA is NOV solution • RTU with FF based Instrument for the Production installation to enable data acquisition and asset management. RTU used is ABB AC800F and Total Flow series. • 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. • 10 No Network Management Station along with firewalls and Routers for all the assets • Disaster Recovery Solution for the Tier 3 SCADA of the corporate data centre. • Scope of Work • Erections and Commissioning of above scope and warranty for one year • AMC of 6 years after warranty

  6. Unique Features of the SCADA Project • Single Largest Instrumentation- Automation – IT Solution project finalised in India – The order value is 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 – 7000 Wells • Single largest contract to build 179 Control rooms, 16 Data centres and 75 Mobile Control rooms at 250 plus locations.

  7. ONGC Assets Spread In India

  8. ONGC Assets Spread In India

  9. The Asset Details • The Asset is a Onshore or an Offshore production facility in that region for the ONGC. • Tier 2 Level SCADA is proposed at the each asset location which will collect the data from Tier 1 SCADA under that asset. • The Tier 1 SCADA will be used for following facilities with in the asset • Group Gathering Stations (GGS) • Gas Collecting Station (GCS) • Central Tank Farm (CTF) • Central Processing Facility (CPF) • Early Production System (EPS) • Gas Compressor Plant (GCP) • Effluent Treatment Plant (ETP) • Water Injection Plant (WIP)

  10. Structure of Production SCADA

  11. TDMA LINK ENGINEERING STATION HMI HMI COLOR NETWORK PRINTER HMI ALARM PRINTER L2 SWITCH CONVERTOR AC800 F AC800 F S800 IO H1 Segments H1 Segments H1 Segments RACK MOUNTED SERVERS REDUNDANT PRODUCTION SCADA SERVER Typical Tier 1 Production SCADA (SCADA Vision) Config To Tier 2

  12. TDMA LINK Typical Tier 1 Drilling SCADA(NOV) Config Existing at Rig side New at Rig side To Tier 2 TOOLPUSHER GEOLAB CHEMLAB Router FW WITS Rig Server w/ Drilling SW Apps + Web Server Database Server Color Inkjet Printer DAQ Sensors Existing Rig Server to be Interfaced to Tier 1 Drilling SCADA on WITSML Protocol

  13. WEB SERVER Typical Tier 2 SCADA (Production and Drilling) Config DATA TO TIER 3 LOCATION ENGINEERING STATION B/W NETWORK PRINTER COLOR NETWORK PRINTER HMI HMI HELP DESK HMI FIREWALL LEASED LINE 2 Mbps ALARM PRINTER (PRODUCTION) FROM TIER 1 TRAINING SIMULATOR • RACK MOUNTED SERVERS • REDUNDANT PRODUCTION SCADA SERVER • REDUNDANT DRILLING SCADA SERVER • DUAL REDUNDANT COMMON DATABASE SERVER • APPLICATION SERVER (PRODUCTION) • APPLICATION SERVER (DRILLING)

  14. Typical Tier 3 SCADA (Corporate Office) Config LEASED LINE 2 Mbps To DRS Site

  15. SCADA Vision Applications- Well Test • Automatic and Manual well test at the Tier 1 GGS and EPS SCADA • Well test Data to be available UPWARD in Tier 2 and Tier 3

  16. SCADA Vision Applications- Mass Balance, Well flow status • Mass balance for the Field to Asset is provided • Mass Balance for the Pipeline is provided • For high flowing wells we are providing well flow status. • Gas Lift Optimisation for the some of the oil wells. This cover Continuous and Intermittent Gas lift

  17. (CBF) Control Builder F Typical Offshore RTU Config To Other RTU Stations Through TDMA (Radio Frequency/V-Sat Link / OFC Link) SCADA Vision Server Radio Terminal Terminal Sever TCP/IP Terminal Sever AC800F RTU TCP/IP Profibus Module FF HSE Module TIER-1 STATION • All AC800F based RTU to have FF and Hart interface. LD800HSE is used for the FFH1 • Maintenance Assist Management in Tier 1 SCADA LD800 HSE RLM PROFIBUS S800 IO With HART S800 IO With HART H1 Segments H1 Segments H1 Segments FIELD SIGNALS THROUGH BARRIERS & RELAYS RTU STATION

  18. Field Instrumentations • Type of Instrument to be supplied are as follows • Mass Flow Meter with NOC – 386 No • Thermal Mass Flow Meter – 178 No • Ultrasonic Mass Flow Meter – 105 • PT,DPT,TT on FFH1– 6000 No • Radar Gauges FFH1 based – 1000 No • Low Power RTU ABB Total Flow XRC series • Well Head Mounted RTU – 12 No • FDT DTM with FBB to be used for the Hart and FF configurations • SCADA Vision to is Used for the Maintenance Assist Management

  19. 800xA in ONGC Organization:- ONGC Limited, IndiaProject :-ONGC Hazira DCS/ESD and APC BU (Oil and Gas),ABB limited, Bangalore

  20. ONGC Hazira – DCS/ESD/APC • ONGC Hazira is a Gas Processing Complex of ONGC • It has LPG, GSP, CPP and Utilities with ABB (Bailey), YIL, Honeywell DCS system installed • ABB, YIL and Honeywell has quoted for the Job • YIL is technically rejected and we became Lowest w.r.t Honeywell system • This order is a replacement of the YIL DCS of the LPG Plant. • We also have N-90 /I-90 system running in the same complex for last 2 decade • Tier 1 SCADA node is also coming up in the Hazira site for hooking this plant information to ONGC Corporate Collaboration Centre in Delhi • First Installation of the 800xA in Public Sector Oil Companies with SIL 2 and SIL3 System

  21. ONGC Hazira – DCS/ESD/APC - Scope • Scope of Supply • Two 800xA systems • 6 PM864 Controller,6 no of PM 865 Controllers, 4500 S800 IO Points • 10 HMI station and 2 ES stations • Safeguard System for the ESD • APC for the LPG Plant – ABB Italy • OPC interface of INFI -90, Honeywell GUS, Yokogawa Centum System • Modbus based instruments through Terminal server • Field Instruments like PT,TT,FT etc. • Scope of Work • Erection and Commissioning of the DCS/ESD system with one Year Warranty • 5 Years of AMC after warranty.

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