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The ABB Solution The ABB Solution for the E&P for the E&P IndustryIndustry

Organization:- ONGC Limited, IndiaOrganization:- ONGC Limited, India

Project :-Project :-Enterprise Wide SCADA System for Enterprise Wide SCADA System for the Production and Drilling Facilitiesthe Production and Drilling Facilities

BU (Oil and Gas),BU (Oil and Gas),ABB limited, BangaloreABB limited, Bangalore

The Organisation ONGC Limited – Oil and Natural Gas The Organisation ONGC Limited – Oil and Natural Gas Corporations limited is a Corporations limited is a NavaratnaNavaratna Public Sector Unit. Public Sector Unit. A Company floated by Government of IndiaA Company floated by Government of India

Listed in BSE (Bombay Stock Exchange) and has Listed in BSE (Bombay Stock Exchange) and has market capitalisations of over 40 billion USD. Single market capitalisations of over 40 billion USD. Single largest company in BSE.largest company in BSE.

It produces 27 MMT Crude Oil and 26 bcm of Natural It produces 27 MMT Crude Oil and 26 bcm of Natural Gas.Gas.

The company has a profit of 2 busd and has Capital The company has a profit of 2 busd and has Capital Expenditure over 4 busd every year.Expenditure over 4 busd every year.

Going aggressively around the world to meet India's Going aggressively around the world to meet India's energy requirement through a subsidiary called OVL energy requirement through a subsidiary called OVL (ONGC Videsh limited). (ONGC Videsh limited).

ONGC also floated a joint venture with LN Mittal Steel ONGC also floated a joint venture with LN Mittal Steel Co (Single largest UK based steel baron) for the E&P Co (Single largest UK based steel baron) for the E&P business and has acquired block in Africabusiness and has acquired block in Africa

Primary business is E&P and now venturing into the Primary business is E&P and now venturing into the Refining and Petrochemicals sectors.Refining and Petrochemicals sectors.

The present E&P Business if spread across the length The present E&P Business if spread across the length and breadth of India and SCADA is envisaged at and breadth of India and SCADA is envisaged at present for Indian installationspresent for Indian installations

Intro – The Organization ONGC Intro – The Organization ONGC Ltd.Ltd.

Enterprise Wide SCADA for all Production and Drilling Enterprise Wide SCADA for all Production and Drilling Facility of ONGC Spread across India and in Arabian Facility of ONGC Spread across India and in Arabian Sea.Sea.

The project is envisaged by core design and The project is envisaged by core design and engineering team of ONGC under the initiative of engineering team of ONGC under the initiative of Chairman of ONGC LimitedChairman of ONGC Limited

Main reason for ONGC to think about such LARGE Main reason for ONGC to think about such LARGE architecturearchitecture Efficient Real time Monitoring of the Production and Efficient Real time Monitoring of the Production and

Drilling Parameters across all the assets in IndiaDrilling Parameters across all the assets in India

Remote control of the production well in case of Offshore Remote control of the production well in case of Offshore platformplatform

Facilitate offline analysis of the Valuable/ High Producing Facilitate offline analysis of the Valuable/ High Producing Wells through third party E&P Applications.Wells through third party E&P Applications.

Provide summarised information to the management for Provide summarised information to the management for effective decision making effective decision making

Total Facelift in the day to day operation of ONGC Total Facelift in the day to day operation of ONGC Production and Drilling facility to improve the efficiencyProduction and Drilling facility to improve the efficiency

The Project EnvisagedThe Project Envisaged

Totally 17 No of bidders took the tender, some of the major are Totally 17 No of bidders took the tender, some of the major are Honeywell India, Yokogawa, Emerson, EIL, L&T, etc.Honeywell India, Yokogawa, Emerson, EIL, L&T, etc.

Only ABB and Honeywell could submit the offer due to short time and Only ABB and Honeywell could submit the offer due to short time and large volumes of the project.large volumes of the project.

With in three week of submission the Honeywell bid was technically With in three week of submission the Honeywell bid was technically rejected on account of qualification criteria in terms of rejected on account of qualification criteria in terms of

No Proven track record of Multi tier SCADA ArchitectureNo Proven track record of Multi tier SCADA Architecture

Non Field bus compliant RTU without Asset ManagementNon Field bus compliant RTU without Asset Management Capability to execute the projectCapability to execute the project

Only ABB Price bid is opened after technical evaluation Only ABB Price bid is opened after technical evaluation

We went for a hard negotiations for 4 months period and finally won We went for a hard negotiations for 4 months period and finally won the order above 10% of ONGC budget.the order above 10% of ONGC budget.

ABB two year plus pre-bid selling of the SCADA and Fieldbus ABB two year plus pre-bid selling of the SCADA and Fieldbus compliant RTU has helped to build the confidence in ONGC and bag compliant RTU has helped to build the confidence in ONGC and bag such a big order.such a big order.

With this order ABB India is a Undisputed leader in upstream oil and With this order ABB India is a Undisputed leader in upstream oil and gas solution in India.gas solution in India.

Competition FacedCompetition Faced

Scope of SupplyScope of Supply Supply of Three Tier SCADA Architecture as Production SCADA and Supply of Three Tier SCADA Architecture as Production SCADA and

Drilling SCADA spread across 19 Assets/252 Locations in India. The Drilling SCADA spread across 19 Assets/252 Locations in India. The

Production SCADA is Production SCADA is ABB SCADA VisionABB SCADA Vision and Drilling SCADA is and Drilling SCADA is NOV solutionNOV solution

RTU with FF based Instrument for the Production installation to RTU with FF based Instrument for the Production installation to enable data acquisition and asset management. RTU used is ABB enable data acquisition and asset management. RTU used is ABB

AC800FAC800F and and Total FlowTotal Flow series. series.

Supply of 16 Data Centres including the corporate data centre across Supply of 16 Data Centres including the corporate data centre across India to enable efficient operation of respective Assets.India to enable efficient operation of respective Assets.

UPS for all the 250 plus tier 1 control room of production and drilling 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.SCADA along with FCBC for 85 no of remote RTU with solar chargers.

SAP, Epinet, VRC- Integrations of Real-time and History Data.SAP, Epinet, VRC- Integrations of Real-time and History Data.

10 No Network Management Station along with firewalls and Routers 10 No Network Management Station along with firewalls and Routers for all the assetsfor all the assets

Disaster Recovery Solution for the Tier 3 SCADA of the corporate Disaster Recovery Solution for the Tier 3 SCADA of the corporate data centredata centre..

Scope of WorkScope of Work Erections and Commissioning of above scope and warranty for one Erections and Commissioning of above scope and warranty for one

yearyear

AMC of 6 years after warrantyAMC of 6 years after warranty

The Scope of Supply and WorkThe Scope of Supply and Work

Single Largest Instrumentation- Automation – IT Solution Single Largest Instrumentation- Automation – IT Solution project finalised in India – The order value is 95 musdproject finalised in India – The order value is 95 musd

Largest three tier network of Largest three tier network of Near real timeNear real time process process data monitoring. The no of HMI Station in a single largest data monitoring. The no of HMI Station in a single largest Network - 1300 Plus HMI Stations and 600 Plus ServersNetwork - 1300 Plus HMI Stations and 600 Plus Servers

Largest Project in term of the FF based Instrumentations Largest Project in term of the FF based Instrumentations and automation solution – and automation solution – 7500 FF instrument and 7500 FF instrument and 850 FFH1 segments850 FFH1 segments

First Ever project with FF and Hart based RTU and Asset First Ever project with FF and Hart based RTU and Asset Management.Management.

Largest project in terms of Field Instrumentation scope of Largest project in terms of Field Instrumentation scope of supply supply

Largest Oil and Gas producing wells connected to the Largest Oil and Gas producing wells connected to the SCADA system – SCADA system – 7000 7000 WellsWells

Single largest contract to build 179 Control rooms, 16 Single largest contract to build 179 Control rooms, 16 Data centres and 75 Mobile Control rooms at 250 plus Data centres and 75 Mobile Control rooms at 250 plus locations.locations.

Unique Features of the SCADA Unique Features of the SCADA ProjectProject

ONGC Assets Spread In IndiaONGC Assets Spread In India

ONGC Assets Spread In IndiaONGC Assets Spread In India

Group Gathering Stations (GGS)Group Gathering Stations (GGS)

Gas Collecting Station (GCS)Gas Collecting Station (GCS)

Central Tank Farm (CTF)Central Tank Farm (CTF)

Central Processing Facility (CPF)Central Processing Facility (CPF)

Early Production System (EPS)Early Production System (EPS)

Gas Compressor Plant (GCP)Gas Compressor Plant (GCP)

Effluent Treatment Plant (ETP)Effluent Treatment Plant (ETP)

Water Injection Plant (WIP)Water Injection Plant (WIP)

The Asset DetailsThe Asset Details

The Asset is a Onshore or an Offshore production facility in The Asset is a Onshore or an Offshore production facility in that region for the ONGC.that region for the ONGC.

Tier 2 Level SCADA is proposed at the each asset location Tier 2 Level SCADA is proposed at the each asset location which will collect the data from Tier 1 SCADA under that which will collect the data from Tier 1 SCADA under that asset.asset.

The Tier 1 SCADA will be used for following facilities with in The Tier 1 SCADA will be used for following facilities with in the assetthe asset

Structure of Production SCADAStructure of Production SCADA

Typical Tier 1 Production SCADA (SCADA Vision) Config

CONVERTOR

HMI HMIENGINEERING

STATION

COLOR NETWORK

PRINTER ALARM PRINTER

RACK MOUNTED SERVERSREDUNDANT PRODUCTION SCADA SERVER

HMI

H1 Segments

AC800 FAC800 F

S800 IO

H1 SegmentsH1 Segments

L2 SWITCH

TDMA LINK

To Tier 2

RouterFW

Rig Serverw/ Drilling SW

GEOLAB

CHEMLAB

Existing at Rig side New at Rig side

TOOLPUSHER

Color InkjetPrinter

DatabaseServer

Sensors

DAQ

WITS

Apps + WebServer

Typical Tier 1 Drilling SCADA(NOV) Config

TDMA LINK

To Tier 2

Existing Rig Server to be Interfaced to Tier 1 Drilling SCADA on WITSML Protocol

Typical Tier 2 SCADA (Production and Drilling) Config

WEBSERVER

TRAININGSIMULATOR

RACK MOUNTED SERVERS

1. REDUNDANT PRODUCTION SCADA SERVER2. REDUNDANT DRILLING SCADA SERVER 3. DUAL REDUNDANT COMMON DATABASE SERVER4. APPLICATION SERVER (PRODUCTION)5. APPLICATION SERVER (DRILLING)

FROM TIER 1

HMI HMI HMI HELP DESK

ENGINEERINGSTATION COLOR

NETWORK PRINTER

B/W NETWORK

PRINTER

ALARM PRINTER

(PRODUCTION)

LEASED LINE2 Mbps

DATA TO TIER 3 LOCATION

FIREWALL

Projection-Display-System

Typical Tier 3 SCADA (Corporate Office) Config

SCADA SERVER(PRODUCTION)

SCADA SERVER(DRILLING)

COMMON DATABASE(on ORACLE)

HMI STATION HMI STATION(Drilling SCADA)

WEB SERVER

ADMIN STATION

LASERPRINTER

EVENTPRINTER

FIRE WALL

COLLABRATION SERVER Network ManagementSERVER

Projection-Display-System

LEASED LINE2 Mbps

To DRS Site

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

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

TCP/IP

FIELD SIGNALS THROUGH BARRIERS

& RELAYS

S800 IO With HART

RLM

H1 Seg

ments

(CBF)Control

Builder F

S800 IO With HART

LD800 HSE

PR

OFI

BU

S

FF HSE Module

Profibus Module

AC800F RTU TCP/IP

H1 Seg

ments

H1 Seg

ments

SCADA Vision Server

TIER-1 STATION

RTU STATION

Through TDMA

(Radio Frequency/V-Sat Link / OFC Link)Radi

o Terminal

To Other RTU Stations

Terminal Sever

Terminal Sever

Typical Offshore RTU Config

All AC800F based RTU to have FF and Hart interface. LD800HSE is used for the FFH1

Maintenance Assist Management in Tier 1 SCADA

Type of Instrument to be supplied are as followsType of Instrument to be supplied are as follows Mass Flow Meter with NOC – 386 NoMass Flow Meter with NOC – 386 No

Thermal Mass Flow Meter – 178 NoThermal Mass Flow Meter – 178 No

Ultrasonic Mass Flow Meter – 105Ultrasonic Mass Flow Meter – 105

PT,DPT,TT on FFH1– 6000 NoPT,DPT,TT on FFH1– 6000 No

Radar Gauges FFH1 based – 1000 NoRadar Gauges FFH1 based – 1000 No

Low Power RTU ABB Total Flow XRC seriesLow Power RTU ABB Total Flow XRC series Well Head Mounted RTU – 12 NoWell Head Mounted RTU – 12 No

FDT DTM with FBB to be used for the Hart and FF FDT DTM with FBB to be used for the Hart and FF configurationsconfigurations

SCADA Vision to is Used for the Maintenance Assist SCADA Vision to is Used for the Maintenance Assist ManagementManagement

Field InstrumentationsField Instrumentations

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800xA in ONGC800xA in ONGC

Organization:- ONGC Limited, IndiaOrganization:- ONGC Limited, India

Project :-Project :-ONGC Hazira DCS/ESD and APC ONGC Hazira DCS/ESD and APC

BU (Oil and Gas),BU (Oil and Gas),ABB limited, BangaloreABB limited, Bangalore

ONGC Hazira – DCS/ESD/APCONGC Hazira – DCS/ESD/APC

ONGC Hazira is a Gas Processing Complex of ONGCONGC Hazira is a Gas Processing Complex of ONGC

It has LPG, GSP, CPP and Utilities with ABB (Bailey), YIL, It has LPG, GSP, CPP and Utilities with ABB (Bailey), YIL, Honeywell DCS system installedHoneywell DCS system installed

ABB, YIL and Honeywell has quoted for the JobABB, YIL and Honeywell has quoted for the Job

YIL is technically rejected and we became Lowest w.r.t YIL is technically rejected and we became Lowest w.r.t Honeywell systemHoneywell system

This order is a replacement of the YIL DCS of the LPG This order is a replacement of the YIL DCS of the LPG Plant. Plant.

We also have N-90 /I-90 system running in the same We also have N-90 /I-90 system running in the same complex for last 2 decadecomplex for last 2 decade

Tier 1 SCADA node is also coming up in the Hazira site Tier 1 SCADA node is also coming up in the Hazira site for hooking this plant information to ONGC Corporate for hooking this plant information to ONGC Corporate Collaboration Centre in DelhiCollaboration Centre in Delhi

First Installation of the 800xA in Public Sector Oil First Installation of the 800xA in Public Sector Oil Companies with SIL 2 and SIL3 SystemCompanies with SIL 2 and SIL3 System

ONGC Hazira – DCS/ESD/APC - ONGC Hazira – DCS/ESD/APC - ScopeScope

Scope of Supply Scope of Supply Two 800xA systemsTwo 800xA systems

6 PM864 Controller,6 no of PM 865 Controllers, 4500 S800 IO 6 PM864 Controller,6 no of PM 865 Controllers, 4500 S800 IO PointsPoints

10 HMI station and 2 ES stations10 HMI station and 2 ES stations

Safeguard System for the ESDSafeguard System for the ESD

APC for the LPG Plant – ABB ItalyAPC for the LPG Plant – ABB Italy

OPC interface of INFI -90, Honeywell GUS, Yokogawa Centum OPC interface of INFI -90, Honeywell GUS, Yokogawa Centum SystemSystem

Modbus based instruments through Terminal serverModbus based instruments through Terminal server

Field Instruments like PT,TT,FT etc.Field Instruments like PT,TT,FT etc.

Scope of WorkScope of Work Erection and Commissioning of the DCS/ESD system with one Erection and Commissioning of the DCS/ESD system with one

Year WarrantyYear Warranty

5 Years of AMC after warranty.5 Years of AMC after warranty.