Introduction to process control

1. Process
Methods of changing or refining raw materials to create end products.

2. Process Control.
Tool that enables manufacturers to keep their operations running within specified limits and to set more precise limits to maximize profitability, ensure quality and safety.

3. Types of Process. a) Discrete

b) Continuous c) Batch

Control Theory
Control Theory revolves around three aspects:
Measurement
Comparison
COMPRESSOR FAN COOLANT

ROOM

Adjustment
Error: The important factors of the Error are its vale, duration and rate.
COMPRESSOR ON-OFF CONTROL

ROOM TEMP SENCE

ERROR SET POINTS

Room Air-conditioner is a simple example of feedback control

Controller output may be programmed to be Proportional to Value, Duration (Integral) or Rate (Differential) of input (error). Accordingly Controllers are named as PID controller.

Process Variable

Controller

Manipulated Variable

SET POINTS

Process Control Elements

Field Instruments
Primary Elements/ Sensors Transducer/ Converter Transmitter

Communication Channel
Signals (Analog, Digital, Pulse) Cables, Connectors etc.
Indicators Recorders Controller System SCADA Systems

Control Room

Field Instrumentation

Field Instrumentation are devices that are connected to the process being controlled and monitored. These are sensors for monitoring certain parameters; and actuators for controlling certain parameters of the system. These instruments convert physical parameters (i.e., fluid flow, velocity, fluid level, etc.) to electrical signals (i.e., voltage or current or digital) readable by the Remote Telemetry units. Outputs can either be in analog (continuous range) or in digital (discrete values).

Instruments & Measurement in Oil Industry

1.

Pressure Measurement Pressure Transmitters Strain Gauge based, b)Pressure Switches

a)

2.

Temperature Measurement RTDs and thermistors, Infrared Radiators, Bimetallic Devices, Lquid Expansion Devices, and Change-of State Devices

3.

Flow Measurement
a) b) c) d) Mass Flow Meter Coriolis Flow Meter. Ultrasonic Flow Meter. Gas Flow Meter.

4 5

Level Measurement Calibrators

Control Room Equipments

Indicators Recorders Controller System Relay based Control System
Digital Logic Gates based systems PLC (Programmable Logic Controllers) Distributed Control System

SCADA Systems RTU

SCADA Servers

SCADA

SCADA system consists of collecting information, transferring it back to a central site, carrying out necessary analysis and control, and then displaying this data on a number of operator screens. The SCADA system is used to monitor and control a plant or equipment. Control may be automatic or can be initiated by operator commands. SCADA systems are used in nearly every industry e.g. steel, power generation and distribution, chemical petrochemical, oil & natural gas, in the house and lately in sophisticated toys too. The size of such systems range from a few 1000 to several thousands of input/output (I/O) channels.

Components of SCADA System

A SCADA system generally comprises of the following : 1. Field Instrumentation 2. Remote telemetry Units 3. Communication Networks 4. Central Monitoring Station.

What is Data Acquisition?

Data acquisition refers to the method used to access and control information or data from the equipment being controlled and monitored. The data accessed are then forwarded onto a telemetry system ready for transfer to the different sites. They can be analog and digital information gathered by sensors, such as flow meter, ammeter, etc. It can also be data to control equipment such as actuators, relays, valves, motors, etc.

What is Telemetry ?
Telemetry is usually associated with SCADA systems. It is a technique used in transmitting and receiving information or data over a medium. The information can be measurements, such as pressure, temperature, flow, level, speed, voltage and current etc. These data are transmitted to another location through a medium such as cable, telephone or radio. Information may come from multiple locations. A way of addressing these different sites is incorporated in the system.

Typical System Configurations

There are two typical network configurations for the wireless telemetry radio-based SCADA systems.

point-to-point point-to-multipoint configurations.

Point-to-Point Configuration
The Point-to-Point configuration is the simplest set-up for a telemetry system. Here data is exchanged between two stations. One station can be set up as the master and the other as the slave.

Point-to-Multipoint Configuration
The Point-to-Multipoint configuration is where one device is designated as the master unit to several slave units. The master is usually the main host and is located at the control room. While the slaves are the remote units at the remote sites. Each slave is assigned a unique address or identification number.

REMOTE TERMINAL UNITS

RTU

Basic operation
The RTU will operate scanning its inputs, normally at a fairly fast rate. It may do some processing such as change of state processing, time-stamping of changes, and storage of the data awaiting polling from the SCADA master. Some RTU's have the ability to initiate reporting to the SCADA master, although more common is the situation where the SCADA master polls the RTU's asking for changes. The RTU may do some alarm processing. When polled by the SCADA master, the RTU must respond to the request, which may be as simple as "give me all your data", to a complex control function to be executed.

Remote Terminal (Telemetry) Units RTU

The SCADA RTU is a (hopefully) small rugged computer which provides intelligence in the field, and allows the central SCADA master to communicate with the field instruments.

It is a stand alone data acquisition and control unit.

Its function is to control process equipment at the remote site, acquire data from the equipment, and transfer the data back to the central SCADA system.

There are two basic types of RTU Single board RTU which is compact, and contains all I/O on a single board Modular RTU which has a separate CPU module, and can have other modules added, normally by plugging into a common "backplane" (a bit like a PC motherboard and plug in peripheral cards).

Hardware functionality in an RTU

The RTU has the following hardware features: CPU and volatile memory. Non volatile memory for storing programs and data. Communications capability either through serial port(s) or sometimes with an on board modem. Secure Power supply (with battery backup). Watchdog timer (to ensure the RTU restarts if something fails). Electrical protection against "spikes". I/O interfaces to DI/DO/AI/AO's. Real time clock.

Software functionality in an RTU contd..

Some method to allow the user applications to be configured in the RTU. This may be simple parameter setting, enabling or disabling specific I/O's or it may represent a complete user programming environment. Diagnostics. Some RTU's may have a file system with support for file downloads. This supports user programs, and configuration files.

Supervisory Control & Data Acquisition System

SCADA

Typical Functionalities of SCADA System

1.

2.
3. 4.

5.
6. 7. 8. 9.

Real Time Data Acquisition Initiating Remote Controls Historization Alarm Generation/ Event Monitoring Man Machine Interface Security/ User management Trending Reporting Interface to MIS/ Third Party Applications

TYPICAL MULTI-TIER SCADA ARCHITECTURE

CLIENTS

CLIENTS

CLIENTS

SCADA SERVER

Tier-2

Tier-1
CLIENTS CLIENTS CLIENTS SCADA SERVER

Radio

ETHERNET

RTU
Radio

Local
CONTROLLERS

RTU
CONTROLLERS

FIELD SENSORS

FIELD SENSORS

Central Monitoring Station (CMS)

The Central Monitoring Station (CMS) is the master unit of the SCADA system. It is in charge of collecting information gathered by the remote stations and of generating necessary action for any event detected. The CMS can have a single computer configuration or it can be networked to workstations to allow sharing of information from the SCADA system.

Man-Machine Interface (MMI)

A Man-Machine Interface (MMI) program will be running on the CMS computer. A mimic diagram of the whole plant or process can be displayed onscreen for easier identification with the real system. Each I/O point of the remote units can be displayed with corresponding graphical representation and the present I/O reading. The flow reading can be displayed on a graphical representation of a flowmeter. A reservoir can be displayed with the corresponding fluid contents depending on the actual tank level. The products support multiple screens, which can contain combinations of synoptic diagrams and text.

The MMI program can also create a separate window for alarms. The alarm window can display the alarm tag name, description, value, trip point value, time, date and other pertinent information. All alarms will be saved on a separate file for later review (refer figure)

Trending
The products all provide trending facilities and one can summarise the common capabilities as follows: the parameters to be trended in a specific chart can be predefined or defined on-line a chart may contain more than 8 trended parameters or pens and an unlimited number of charts can be displayed (restricted only by the readability) real-time and historical trending are possible, although generally not in the same chart

historical trending is possible for any archived parameter zooming and scrolling functions are provided parameter values at the cursor position can be displayed The trending feature is either provided as a separate module or as a graphical object (ActiveX), which can then be embedded into a synoptic display. XY and other statistical analysis plots are generally not provided.

A trending of required points can be programmed on the system. Trending graphs can be viewed or printed at a later time. Generation of management reports can also be scheduled on for a specific time of day, on a periodic basis, upon operator request, or event initiated alarms

Logging/Archiving logging can be thought of as medium-term storage of data on disk archiving is long-term storage of data either on disk or on another permanent storage medium. Logging is typically performed on a cyclic basis, i.e., once a certain file size, time period or number of points is reached the data is overwritten.

Logging/Archiving contd.

Logging of data can be performed at a set frequency, or only initiated if the value changes or when a specific predefined event occurs. Logged data can be transferred to an archive once the log is full. The logged data is time-stamped and can be filtered when viewed by a user. The logging of user actions is in general performed together with either a user ID or station ID. There is often also a VCR facility to play back archived data.

Report Generation One can produce reports using SQL type queries to the archive, RTDB or logs. Although it is sometimes possible to embed EXCEL charts in the report, a "cut and paste" capability is in general not provided. Facilities exist to be able to automatically generate, print and archive reports

Automation The majority of the products allow actions to be automatically triggered by events. A scripting language provided by the SCADA products allows these actions to be defined. In general, one can load a particular display, send an Email, run a user defined application or script and write to the RTDB. The concept of recipes is supported, whereby a particular system configuration can be saved to a file and then re-loaded at a later date. Access Control Access to the program is permitted only to qualified operators. Each user is given a password and a privilege level to access only particular areas of the program. All actions taken by the users are logged on a file for later review

Scalability

Scalability is understood as the possibility to extend the SCADA based control system by adding more process variables, more specialised servers (e.g. for alarm handling) or more clients. The products achieve scalability by having multiple data servers connected to multiple controllers. Each data server has its own configuration database and RTDB and is responsible for the handling of a sub-set of the process variables (acquisition, alarm handling, archiving).

Data Transfer & Communication in SCADA

Communications in SCADA
Internal Communication

Instrumentation to Controllers Foundation Fieldbus etc)

Controllers to SCADA Servers In-between SCADA Servers

(4-20

mA,

HART,

External Communication

Communication with Third Party Applications

Communications Channels / Modes

Directly Connected on LAN This is mostly applicable in PC based local SCADA systems. Used in Drilling Rigs, and Onshore Production Installations such as GGGs, GCS

Connected through Radio/ Telephone / VSAT These cannels are used for Remote Stations. Used in Offshore Unmanned Production Platforms and Onshore Remote Production Installations.

Some Industry Standard Communications Protocols

MODBUS

MODBUS protocol is a messaging structure widely used to establish Master Slave communication between intelligent devices. It is independent of underlying physical layers. It is traditionally implemented using RS232, RS 422 or RS485 over a variety of media (eg. Fiber, radio). MODBUS TCP/IP was recently developed to provide a faster interface and uses TCP/IP and Ethernet to carry the MODBUS messaging structure. It requires a license but all specifications are public and open so there is no royalty paid for the license.

Some Industry Standard Communications Protocols

DNP-3

DNP was originally created by Westronic in 1990. DNP 3.0 is an open, intelligent, robust and efficient modern SCADA protocol. It is based on the standards of the INTERNATIONAL ELECTROTECHNICAL COMMISSION(IEC) Technical Committee. It is used to exchange data between RTUs and Remote central points DNP3 is an open and public protocol

Some Industry Standard Communications Protocols

ICCP

ICCP maximizes the use of existing standard protocols in all layers up to and including the lower layers of layer 7 in the OSI reference model. This has the benefit of requiring new protocol development for ICCP only in the upper sublayer of layer 7.
ICCP utilizes the services of the Application Control Service Element(ACSE) in layer 7 to establish and manage logical associations and connections between sites. It relies on the ISO Presentation Layer 6 and Session Layer 5 as well.

Some Industry Standard Communications Protocols

OPC (OLE for Process Control)

OPC(OLE for Process Control) is a software standard for open software application interoperability between automation/control application, field systems/devices and business/office applications. OPC defines a common, high performance interface based on Microsofts COM/DCOM technology. COM(Microsofts Component Object Model) enables the definition of standard objects, methods and properties for servers of real time information such as DCS, PLCs, I/O systems and smart field devices. DCOM(Distributed Component Object Model) is the network-aware version of Com technology, providing data via LANs, remote sites or the internet.

Application Interfaces / Openness

The provision of OPC client functionality for SCADA to access devices in an open and standard manner is developing The products also provide an Open Data Base Connectivity (ODBC) interface to the data in the archive/logs, but not to the configuration database, an ASCII import/export facility for configuration data, a library of APIs supporting C, C++, and Visual Basic (VB) to access data in the RTDB, logs and archive. The API often does not provide access to the product's internal features such as alarm handling, reporting, trending, etc.

Communications External to SCADA System

Communication with Third Party Applications ODBC (Open Database Connectivity), JDBC, XTML etc

Enterprise Application Interface / Enterprise Service Bus

Application Interfaces / Openness

The provision of OPC client functionality for SCADA to access devices in an open and standard manner is developing The products also provide an Open Data Base Connectivity (ODBC) interface to the data in the archive/logs, but not to the configuration database, an ASCII import/export facility for configuration data, a library of APIs supporting C, C++, and Visual Basic (VB) to access data in the RTDB, logs and archive. The API often does not provide access to the product's internal features such as alarm handling, reporting, trending, etc.

Communications External to SCADA System

Communication with Third Party Applications ODBC (Open Database Connectivity), JDBC, XTML etc

Enterprise Application Interface / Enterprise Service Bus

Applications of SCADA

SCADA From the cold of Siberia to the heat, salt and moisture of offshore oil platforms, SCADA (Supervisory Control and Data) systems are proven performers in a wide variety of industries and applications.

Oil & Gas Production & Drilling. Oil refineries Electrical Generation, Transmission & Distribution Chemicals & Petrochemicals Fertilizers Water Distribution Sewerage

END USERS OF SCADA DATA

1. At Production Facilities such as Well Head Platform , Process complex. 2. At Drilling Rigs 3. MIS at reports on Production facilities 4. MIS reports from Drilling Rigs Operators and In-charges of the facilities Drillers, Drill site Geologist, Chemist and DIC Production Operations Managers Drilling Operations Managers

5. Corporate Office

Chief of Production & Drilling Directors and C&MD of company

R&D Institutes

6. Remote Users

Applications of Drilling SCADA

Software packages are available performing offline calculations of Drilling Parameters related to the following:
Bottom Hole Assembly Casing design Cement Cost Modules Drilling & Drill String Mechanics

Mud Control
Well Control Well path

Monitoring of Following type of wells

- High Oil Producers - Critical Wells - Observation Wells

PT
Comparison of Well & Header Pressure
6.6 6.4 6.2 6 5.8 5.6

Pressure in Kg/cm2g

PT

Header Pressure Well Pressure

13

17

Time in Hours

Comparison of Well & Header Pressure

Pressure in Kg/cm2g
7 6.5 6 5.5 Header Pressure Time in Hours

10

13

16

19

Time in Hours

22

21

Computer aided automatic Well Testing

Injection Gas In

Produced Hydrocarbon Out

Side Pocket Mandrel with Gas Lift Valve Side Pocket Mandrel with Gas Lift Valve Side Pocket Mandrel with Gas Lift Valve Completion Fluid Single Production Packer

ON-LINE OPTIMISATION AND CONTROL OF GAS-LIFT WELLS BY ASSET

TEST Gas Flow Meter TEST HEADER

Test Separator
FLOW SENSOR FT TEST Oil Flow Meter

ANNULUS VALVE

H.P. GAS LINE

RTU
Downhole Parameters

Modified Set-up

Gas Lift Optimization

950

GAIN IN OIL RATE=80bbl INCREASE IN GI RATE=12000SCMD

900 Oil Output (BOPD)

AFTER STUDY
66880, 889

850

RANGE OF PROD. BEFORE STUDY

56520, 847 75367, 822

800

750 49184, 709 39783, 695

700

650 39783

49184

56520 Gas Input (SCMD)

66880

75367

Control Room at Asset HQ

POINT TO POINT TRUNK PIPE LINE

MASS BALANCING BY USING SOFTWARE AND AVAILABLE INSTRUMENTATION
AT EITHER ENDS OF PIPE LINES

MMIS MASS BALANCING

Pressure, Temp, Total Qty & Water Cut of Oil Dispatched to Uran

Pressure, Temp, Total Qty & Water Cut of Oil Received

LKW-CTF PIPE LINE

MORAN

COMPUTER ASSISTED MONITORING OF ESP

Optimal Pumping System

The objective is to maximize the production without damaging the formation Production optimization and protection of the system through the proper speed control as function of:

Pump and motor temperatures Fluid level conditions Pressure (absolute and differential pressure measurements in the system) High and low pump torque

Shut down backspin control

MIS DELHI

GENERATION OF REPORTS BY SCADA

ASSET DPR
Field DPR Field DPR

DPRs from GGSs & GCS

DPRs from GGSs & GCS

Field DPR

DPRs from GGSs & GCS