awt overview
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AWT OverviewAWT Overview
Duri Automatic Well Test
PT. Caltex Pacific Indonesia
Sukis Haryanto
DURI WELL TEST FACILITIESDURI WELL TEST FACILITIES
1
8
1311
10
12
9
7
23
4 5
6
Area # of Quadrant # of Train # Well Address
4 5 10 520
5 4 12 624
6 4 8 424
7 5 10 600
8 2 6 347
9 4 8 608
10 4 8 400
11 1 7 280
Total 29 69 3803
ResourcesResources
Controllers– GE Fanuc, GE-9030
• Areas 4,5,6,9
– Allen Bradley, PLC5/30• Areas 7,8
– ABB Bailey
SoftwareSoftware
Database– Oracle
Ladder Logic Development Software– Logic Master 90– RS Logic 5 V 2.0– Freelance 2000 DigiTool
MMI Development Software– Wonderware Intouch v 7.0– Freelance 2000 DigiVis
Field Automation ComponentField Automation Component
CPI NETWORK
DURI CONTROL ROOM COMPUTER ROOM
DATASERVEROPERATOR
REMOTE VIEWER
CONTROLLER
MMI & PrinterOperator Station
Co
mm
Me
dia
• Actuator• Water Cut Probe• Control Switch• Etc.
Communication Media• Fiber Optic• Wireless LAN• Dial up• Microwave• Radio
IDDRINTSCADA01IDDRIUXDB1DREAMS
AWT Process DiagramAWT Process Diagram
WELL TEST PRIORITYCRITERIA:1. WELL WORKED2. % DIFFERENCE OF BFPD WITH 5 PREV. TESTS.3. % DIFFERENCE OF CUT WITH 2 PREV TEST3. LAST TEST DATE4. SURFACE EQUIPMENT CHANGES
DREAMS DURI-FA
WTCP SENSOR
DATA COLLECTION
PRIORITY
WELL WORKSE CHANGES
TEST RESULTS
ENGINEERING- DATA ANALYSIS
OPERATION- MONITOR AND- CONTROL TEST STATION- OVERRIDE PRIORIY
AWT Typical PipingAWT Typical Piping
PUMPING UNIT
TO CGS
TO SLOP OIL
FOULED HEADER
MICROMOTION CUT PROBE
NOC
GAUGEPUMP
GAUGE SEPARATOR
GAUGE TRAIN 1
TEST LINE 1
TEST LINE 2
MANIFOLD A/B
CUT PROBE
NOC
PUMPGAUGE
GAUGE SEPARATOR
GAUGE TRAIN 2
TEST LINE 1
TEST LINE 2
MANIFOLD C
CUT PROBE
NOC
GAUGEPUMP
GAUGE SEPARATOR
GAUGE TRAIN 3
TEST LINE 1
TEST LINE 2
MANIFOLD D
F2F1
F2F1
F2F1
MICROMOTION
MICROMOTION
LSLL
LSL
LSH
LAH
F3
LSL
LSH
LSLL
LSL
LAH
LSLL
LSL
LSH
LAH
F3
F3
BPCV
BPCV
BPCV
10 Steps of Automatic Well Test10 Steps of Automatic Well Test
IdleSending ParameterPurging IPositioning valveFlushingGaugingClosing valvePurging IISand jet valve openSand jet pump on
Well test process is executed by PLC but it is started by MMI.
Automatic Well Test ProcessAutomatic Well Test Process
Start
Duri-FAServer
Well Test CandidateSelection Process(1)
Well TestCandidates
Operator2
Abort
Record in Gauging.txt
Test TrainOn ?
Yes
No
3
AbortTest?
Purge IGauging Tank
Wait currentProcess
Yes
No
SystemIdle?
No
Yes
7/8
Level below LAHBefore Max Limit of
Purging time?
Yes
No
18
Well ValveOn?
NoAbort and Record in Gauging.txt 5
Yes
Open Configuration ValveTo Test Line
Success?
Yes
No
11
Open Well Valve toTest Line
Flush tank till reach time periodand pump fluid till below LSL
Success?
Yes
No
11
Abort
Yes
NoFluid Level
Reach LSH?Wait
Start Pump
Pump RateGT Min Rate?
Yes
No
12
Totalize Oil & WtrCalculate WCAverage Temp.
Any Reading on
NOC?
Yes
No
17
FluidLevel Reach
LSL ?
Yes
No
Shut off Pump
ReachGauging Period?
Yes
No
Close valves & start pump
Total VolumeCalculate WCAvg Temp
Test Line ON ?
Yes
No
4 FluidLevel Under
LAH ?
Yes
No
10
21
SendingParameter(1 minute)
Fill Gauging Tank
Fluid LevelReach LSL before
Time limit
No
20
BPCV pressureSwitch Closed ?
Yes
No
22
Success?
Yes
Abort
No
13
No under no choice indicate status code
Field Data CollectionField Data Collection
PLC
Flow Sensor
Water Cut Sensor
Flow Transmitter
InOut
In Out
Pulse (Total Oil)
Current(4 - 20 mA)Pump Rate
Current(4 - 20 mA)Pump Rate
Pulse (Total Oil)
Net Oil Computer
Completion StatusCompletion Status
Automatically InitiatedManually Initiated
Aborted Because The Test Train Was Off-LineAborted Because The Test Line/ Configuration-Valve Was Off-
LineAborted Because The Well/ Control-Valve Was Off-Line
Cannot Read Temperature MeterStopped By OperatorAborted By Operator
Aborted Due To Priority Leak TestAborted Due To High Fluid Level In Separator
Aborted Due To Valve ErrorAborted Due To Low Flow Rate
Aborted Due To Test Train Pump Shut Off Failure Even The Fluid Is Below LSL
Aborted Due To Emergency Automation ShutdownAborted Due To Ac Power For Field Devices Failure
Aborted Due To Ac Power For Controller Voltage FailureAborted Due To Error Reading Instruments
Aborted Because The Wtc Was Unable To Purge The SeparatorAborted Due To High Production
Aborted Due To No Flow Into SeparatorNormally Completed
Aborted Due To Bpcv Fail
0 = No1 = Yes
Automatic Well Test Data FlowAutomatic Well Test Data Flow
GaugingProcess
Well TestResults
LoadingProcess
Selection Process
AcceptableTests
RejectedTests
Gauge_ResultTable
Transfer Process
Evaluation Process
Dreams
Rejected Test Criteria•Fluid greater than 3000•Fluid is 100% higher than average last 5 tests•Water Cut is 25% diff. From last 2 tests.
Major Changes on Duri AWTMajor Changes on Duri AWT
Spot metering BPCV installation Density meter installation Automatic sequence method Downtime data collection Valve status information and data
collection Header Pressure data collection Additional infill producers
SelesaiSelesai
Terima kasih
IdleIdle
Condition state where there is no PLC activity– Intentionally put it idle by operator– Declared by PLC after it complete one(1)
cycle of process without any error– Declared by PLC when there is alarm
on critical component.
Sending ParametersSending Parameters
A state when MMI is writing well testing parameters into PLC memory– Operation Mode– Test Duration– Flushing time– Purging Time– Below XLSLL time– Before sand jet closed– Before activate pump– Sand Jet failure retry
Purging IPurging I
PLC state when the system puts fluid level at XLSLL (stop when fluid level at XLSLL)– Failure that may happen
• Unable to purge the separator– Gauging pump did not start
– Pumping time exceeds limit
• Pump shut off failure• Low pump flow rate
– Gauging pump rate is less than certain value. The value is defined by operator
Positioning valvePositioning valve
Moving valve into test line by supplying air into its actuator– Failure that may happen
• Valve Error– System commands to open a valve, but valve
does not response after certain seconds. This is indicated by limit switch signal
• Impact of valve error– Stop process and put test line where the valve
the valve is hooked-up into OFFLINE
FlushingFlushing
Flushing process replaces fluid left in the test line from the previous well with fluid from the well that will be tested and keep the fluid level at LXSLL– Failure that may happen
• High Production– Production rate is greater than gauging pump capacity.
• Leaking valve• Sand jet valve open• High production rate
– Impact – Stop current process and skip to next candidate
• Unable to purge the separator (put test train off)• Pump shut off failure (put test train off)
GaugingGauging
Gauging is a process of filling well test separator with fluid from well. This process stops after gauging period is complete. The process will reset oil and water counter– Alarms that may happen
• High fluid level in separator– Fluid level reach LAH, indicated by level switch
• Error reading instrument– There is flow rate but no fluid available.– No flow rate but there is fluid available.– Current signal from micromotion meter exceeds limit
• No flow in separator– There is no fluid in separator after certain period of time
indicated by LXSLL. The period is defined by operator.
Closing ValveClosing Valve
Moving valve into prod line by releasing air supply in its actuator– Failures that may happen
• Valve Error– Valve position is not back to production line after
air supply is release from the actuator. This is indicated by limit switch signal
• Impact of valve error– Stop process and put test line where the valve
the valve is hooked-up into OFFLINE
Purging IIPurging II
A process of pumping fluid from separator while accumulating total oil and total water until fluid level is back at LSXLL.– Alarms that may happen
• Unable to purge the separator• Low pump flow rate• Error reading instrument• Shut off pump failure
Sand Jet Valve OpenSand Jet Valve Open
A process of flowing kill water into tank bottom to keep it from sediment after doing well testing process– Alarm that may happen
• Valve error• Sand Jetting Failure
Sand Jet Pump OnSand Jet Pump On
Pumping fluid from tank bottom
Data Acquisition ProcessData Acquisition Process
Alat-alat Lapangan PLC Aplikasi WonderwareAplikasi Layanan I/O
Pemberi sinyal danpelaksana perintahdari PLC
Pengatur dan pemberiperintah kepada peralatandi lapangan
Mengenalkan sinyal PLCkepada aplikasi Wonderwaredan sebaliknya
Memerintah PLC, menerimasinyal dari PLC, mengolahmenterjemahkan danmengvisualisasikan di Layar PCserta menyimpan informasidalam workstation.
Skill Requirement for SCADA Skill Requirement for SCADA MaintenanceMaintenance Operational Process Computer Literacy Scada Concept Instrumentation & Control Process Control Field Instrument Motors & Drives System PLC Programming HMI/MMI Design & Programming Data Communication Database Office & Plant Network Integration
Well Test ControllerWell Test Controller
ENG
AlarmPrinter
MMI & PrinterController
Well Test Station
Note :• Area 1 thru 3 Manual Well Test• Area 4 thru 9 Automatic Well Test( Communicate to Radio & Micro Wave )
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