Awt Overview

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 )