Solutions for Oil&Gas industries

Transcription

1 Solutions for Oil&Gas industries

2 Upstream offshore pages 6-9 Upstream onshore pages Midstream pipeline pages Downstream: refineries, petrochemicals complexes & LNG plants pages

3 Solutions for Oil&Gas industries Black gold, expensive and rare With 25% of the energy consumed in the industry worldwide, Oil&Gas is the most energy intensive industry. From offshore and onshore to storage and transport, Schneider Electric Oil&Gas provides secured and safe solutions to boost your performance through energy management while preserving the planet. Secured and safe solutions You want to manage risks and unexpected events to ensure the safety of your people and your environment. We secure your production and assets. High process performance through advanced energy management solutions Energy consumed by the O&G industry represent ~10% of the gross O&G production. Schneider Electric has the expertise for Energy Management to recommend purpose-designed solutions to reduce your capital spending and operating cost. We do what it takes to guarantee the integrity of your energy even in areas considered inaccessible. Customized solutions for offshore, onshore, pipelines and refineries You work in extreme conditions, safety, security, energy management and costs are your major challenges. Our international experts help you choose reliable solutions that are perfectly suited to your needs. 3

4 l Solutions for Oil&Gas industries Effective and customized the Oil&Gas processes Thanks to its expertise in energy management and its ability to provide safe and secure solutions for people and assets, Schneider Electric gives the relevant answer to your challenges: > Optimize your investments > Increase the life of equipments > Guarantee the availabilty of your processes > Improve people and machines safety > Contribute to the sustainable development. Oil field management Pump control unit for rod-pump and PCP Onshore scattered oil field pumps automation Onshore scattered oil field power supply Oil sands mining process control E-House for oil sands mining sites Offshore safety Sub-sea power distribution module Top side E-House Platform harmonic solution Medium voltage architecture dependability study Harmonics mitigation solution 4

5 solutions all along Pipe management Pipeline boosting station control system Tank farm control and automation solution Pipeline boosting station E-house Safety solution for Oil&Gas pipeline Leak detection Energy monitoring and control system for Oil&Gas large sites Critical power system solution: monitoring energy availability and quality Entreprise energy management integrating process Integral security solution from access control to intrusion control and CCTV 5

6 6 No time for unexpected events

7 > Upstream offshore Extracting the oil offshore is even more difficult than onshore; the time where sub-sea drilling was at a short distance from the shore or the surface is over, and today companies have to search deeper, further, requiring solutions for higher power and process availability, in harsh environment: salty, wet, and unstable. The platforms are built in specific and few construction yards, well exposed to the sea, with enough draught. Time and space are critical issues. The construction time is strictly planned, with a tight schedule. All equipments must be delivered on time to make sure the platform can get to sea quickly. One day s delay meaning one day production loss. Oil companies are looking for partners able to respect their delivery times and require reliable solutions, with proven and off the shelves equipment. The value of expertise With its expertise in energy management, Schneider Electric offers pre-tested solutions saving time and footprint, square meters on board being so tightly numbered. All our concerns are dedicated to help customers making the most of their energies with a clear focus on efficiency, communication and maintenance. Our electrical house system, E- House, for power supply, contains all the necessary MV and LV equipment. Thanks to its modular way of building, all electrical parts are pre-tested, and set in a prefabricated technical room integrating control and safety systems to monitor the process. On the process side, Schneider Electric through its wide experience in nuclear industry has acquired a unique expertise in safety PLCs. Our certified experts provide high-skilled services, such as on site risk surveys, or HAZOP. At the forefront of our customer technological challenges, we are developing new solutions to supply the energy or protect electrical equipment in demanding environment, such as seabed platforms 3000 m under the sea level. 100 M$ to 1,000 M$ is the cost for offshore platforms 7

8 Offshore We make energy safe, reliable, productive and efficient Control simple or complex electrical networks Schneider Electric s Energy Management and Control System (EMCS) provides safety, continuity of service and cost-saving for all electrical distribution network architectures. EMCS, compliant with IEC 61850, integrates the supervision and monitoring of all the electrical equipment. Our EMCS system can be used to control simple or complex electrical networks : > Control the link with the power distributor > Optimise the operation of the electrical system. Our EMCS incorporates communication with all the installed electrical distribution equipment, including third-party equipment with recognised protocol. It also interfaces with high-level information systems (ERP). Schneider Electric provides all electrical distribution equipment, to be used with all MV and LV network supplying processes (motors), utilities (water, gas, electricity) and premises or facilities on board. > GIS or AIS MV/MV substations > MV/LV substations > ipmcc > LV Motor Control Centre > LV Power and Motor Control Centre > LV switchboard > Secured power. Integral safety for offshore platforms To provide availability and safety to both personnel and machines, Schneider Electric has developed integrated architectures to cover various applications such as emergency shut down systems (ESD), fire and gas systems (F&G), burner management systems (BMS) and boiler protection. For the offshore industry, Schneider Electric has designed a unique solution based on the Quantum Safety PLC.This solution, aimed at medium-size drilling or production platforms, consists of an integrated and embedded ESD process, F&G systems and building fire systems to monitor and automatically initiate the appropriate action in case of any fire and gas hazards on the platform. Any such incident or unexpected event is stored in a sequence of events file, reported to the security and control room and dynamically displayed on a CITECT HMI (Human Machine Interface) device. Secure power is supplied via a GUTOR hardened and redundant UPS, and some of the instrumentation is taken from the TAC/PELCO line of products. 400 platform/year under building 8

9 Schneider Electric awarded for the complete power management system of Pazflor FPSO (Angola) The Total Floating Processing, Storage and Offloading unit (FPSO) will process the oil via 49 sub sea wells, in depth between 600 and 1,200 metres. It will have a processing capacity of 200,000 barrels of oil per day and a storage capacity of 1.9 million barrels. Our power management system will secure non-stop operation, control critical loads and maximise people and assets safety. 9

10 10 Getting the most of your well

11 > Upstream onshore Today s oil pumps, whether new or existing, need to be controlled by a system that provides solutions to maximize pump efficiency and productivity and avoid costly downtime. A part from some places where the oil is eruptive, energy is a condition to extract the oil; and it is even a challenge in cold environment with very low temperatures, since the density of the oil makes the extraction difficult. Electrical power supply is also an important part of oil and gas companies Opex. With oil prices increase, a large number of companies are reactivating wells to both improve production capabilities and increase the performances of the actual active production wells: enhancing oil recovery, optimising continuity of service and reducing mechanical stress on the machines. When talking about pump, it is not only oil extraction. In any oil field pumps exist for different uses, water injection is an example, and each ones has different characteristics. Caring of these differences, our solutions will increase the total process performance. Obtain more than only oil production Our expertise rely on our ability to manage the energy to make the oil field as efficiently as possible, reducing the electrical and mechanical stress on the machines, and anticipate some eventual inconvenient what could stop the production. In other words: making the use of their energy more efficient. We focus our solutions on three main points: > Extend the machine s life, using the correct electric control and protection device to avoid machinery stress and other mechanical and electrical problems. Motor Temperature, rod and belts broken and safety, are some of the most important elements to take care of, and the pump power, control and protection device must be able to do it. > Anticipate the event, getting precise information regarding the machine operation status and historical data, to anticipate the problems and take the actions to minimize the losses. The current evolution, torque, running time, pressure and temperature provide valuable information to know what happened and to decide the best action to take. Anticipation reduces production downtime and maintenance cost. 100 barrels of oil per well is the average production loss of 24 h without energy > Optimize Pumping, based on online data and the controller intelligence to adjust the pump working parameters like speed, time, torque, and others, to reach the best production performance. Many solutions based on Schneider Electric equipment have been installed in oil fields for more than 8 years with excellent results. The speed drives, soft and direct starters include specific functions for any kind of pumping applications like ENA system for onshore pump jack and torque limitations for PCP. 11

12 Onshore Make the energy available wherever at anytime Energy often means continuity of service and efficiency, two issues constantly present in oil fields continuous production process; that is to say oil barrels production. Our solutions include the entire MV and LV electrical power network equipments. Monitoring, failure indicators, automatic switch, transformers, LV power motor protection and electrical SCADA systems are examples of solutions developed by our experts and specially dedicated for the O&G market, where those have already been approved by the users for many years. Maximise pump efficiency and productivity When there are abundant oil reserves in the ground, the pumps run almost 100 % of the time as maximum speed as possible. However, when wells have a low recovery time or a non constant flow, pumps can only run a portion of that time or producing a limited amount of oil. The power control solution for pumping oil, include a VFD (Variable Frequency Drive) to help and create an uninterrupted flow of oil, reducing downtime and energy costs. The drive creates smooth starts and stops, which reduces energy costs compared to direct online (DOL) starters. In addition, the VFD reduces mechanical stress associated with DOL starting, creating more reliable pump operation and fewer equipment failures. The Energy Adaptation System (ENA) is another solution. The Altivar ENA system is developed especially for protecting and commanding oil Pump-Jack, avoiding the motor regeneration. Reducing the polish-rod and the gearbox stress, it extends the machine life and avoids the production stops, increasing efficiency. In addition, the variable speed driver gives the pump-jack motor the necessary frequency for adjusting the strokes per minutes of the machine with no intervention in the well. Similar solutions are developed and installed for PCP and ESP pumps in different oil fields. In Argentina, Schneider Electric has developped a new solution to increase the oil field production and the performance in PCP units The core solution is a robust electrical power management unit, to provide a precise pump speed and torque control and with a smart configuration interface. Mainly, the variable speed driver gives to the PCP motor the necessary frequency for adjusting the speed of the pump to the best RPM value anytime, to optimize production and avoid mechanical stress. The VFD also adjusts the RPM automatically to avoid problems of over load in the rod string due to pump stuck, line obstruction etc, or under load due belt breakage, also manage the back spin effect on start up, to protect the pump, the rod string, and maximize production. All of this features resulting in a remarkable increase in the efficiency and performance of the well. 12

13 Scattered Oil Field Management The size of oil fields, the range of installed products, and the number of pumping and control points determine the complexity of oil production field monitoring system. The heart of a monitoring system is the supervisory control and data acquisition (SCADA) system. This gives a big picture overview of all the oil field activities and allows the operator to know what is happening in the entire installation from a single control centre. Essentially a central control room where the Process SCADA system (Vijeo Citect) is collecting information provided by a lot of Remote Terminal Units (RTU) in the field, allows monitoring and control of the wells, the electrical distribution networks and all the different parts of the process from one single location. All this information helps maintaining the oil field fully operational, anticipating the events and sharing the relevant information with other areas of the company. 13

14 14 The safest way of transportation

15 > Midestream pipelines Pipelines are the safest, most reliable and cost-effective way of transporting large volumes of oil and gas. Pipeline systems link typically remote production fields to urban centres and/or terminals and ports for export. More than 60 kinds of unprocessed and refined petroleum move through pipelines. The pipeline company or operator are under pressure to operate with the highest level of pipeline integrity, safety, security & reliability while meeting demanding delivery schedules reducing capital, operational and maintenance costs and ensuring regulatory & environmental compliance. Your pipeline system links Oil&Gas produced in remote production fields concentrated through gathering lines with refineries, terminals or distribution. The system may have multiple sources of crude or gas, storage and delivery points linked through a system comprised of pump or compressor stations, block valve stations, metering stations and terminals and it s corresponding control center. The secure, efficient operation of the pipeline network requires real-time monitoring, precise control, energy management and integral security & safety. Your new capital projects and expansions require to be delivered on-time, on budget and at the highest quality to ensure contractual commitments, proper time-to-market and proper investment returns. Enhance your pipeline integrity and maximize your performance Our advanced Energy Management, Integral Security and Process Automation Solutions - are designed so our customers can improve their safety, security and performance while reducing total cost of ownership and lowering the environmental impact and energy consumption of their pipeline operations. Schneider Electric combines the competencies of global specialist in Energy Management with strong process automation, Integral security offer and our best in class Project Management & Services organizations to serve the pipeline Industry on a global basis achieve their business and operational objectives. We have extensive experience, global capabilities and local presence, and deliver turn-key projects that results on efficient, safe and profitable operations for our customers including robust leak-detection systems, cathodic protection and intrusion detection systems to ensure pipeline integrity. 2 M km of pipelines throughout the world 1 hour pipe shutdown = a loss of 30,000 barrels 15

16 Pipelines Our capabilities and expertise Schneider Electric experience in providing process automation, electrical solutions and integral security includes front-end-engineering (FEED), conceptual design through implementation and commissioning of SCADA, station automation, safety systems, Medium Voltage & Low Voltage electrical and drives systems, Energy Monitoring, Integral Security (leak-detection, cathodic protection, digital video systems, intrusion detection, Fire&Gas) and integrating flow metering, instrumentation & telecommunication systems. Schneider Electric experiences encompasses pumping & compressor stations, block valve stations, metering stations. Our pipeline management solution Our scalable, proven and flexible architecture is based on our leading SCADA and PLC & RTU offers with field instrumentation, measurement, information technology, pipeline modeling, and telecommunications components, coupled with Schneider Electric Project & Engineering services and industry expertise on the pipeline industry. > Control Centres: our solution consists of our leading edge SCADA platform, with redundancy and a suite of pipeline management application like leak-detection systems and cathodic protection monitoring; pipeline energy management, measurement integration, and decision support applications. Full integration of our Power SCADA & Monitoring offer with our Integral security application is achieved at the SCADA center. For your datacenter & infrastructure needs we offer state-of the art UPS & Cooling system ensure your uptime & reliability. > Pump or compressor station: our solution consists of our leading PLC platform, available in hot stand-by configuration, supported by Schneider s suite of control strategies; and platforms for local device integration, HMI/operator interface, drives systems, Cameras/CCTV and access control provide integral security to the installations, and wide-area network communications. Our Electrical Distribution Switchgear for Medium Voltage & Low Voltage, power monitoring & control equipment, harmonics filtering, UPS system - ensure the Energy availability, uptime, reliability and Energy Management for reliable operations. > Meter station: we can provide the best metering system for the specific application (from orifice, turbine, or ultrasonic for gas or positive displacement, turbine, mass flow for liquids). Our PLC s and RTU s/electronic Flow Measurement devices interface with the meter and perform industry standard (AGA, API) flow calculation algorithms. The metering station data is then integrated in our information validation and metering application providing a measurement solution that ensures accuracy, reliability for fiscal and custody transfer. > Block Valve stations: our RTU Interface to field instruments (temperature pressure and flow) provide block valve, actuator status actuator status; block valve control and communications to the SCADA systems. 16

17 Schneider Electric ensures the safety, reliability and uptime of the longest pipeline in China The 4,000 km long pipeline transports natural gas from Xianjiang, West China to Shanghai, East China. It is controlled through a central SCADA System monitoring compressor and block valve stations along the pipeline with Schneider PLC s and ruggedized RTU s. The Schneider Electric solution allows all services in a all-in-one network and automatic data transfer from primary to standby PLC controllers without any specific configuration. Our redundant architecture meets the requirement of 24/7 system operation to ensure pipeline safety and integrity. 17

18 18 More production with less energy

19 > Downstream: refineries, petrochemical complexes & LNG plants The petroleum or the crude oil is the term for unprocessed oil. That means the primary product, a complex mixture of different types of hydrocarbons like Paraffins, Aromatics, Napthenes and Alkenes, that comes out of the ground ora drilling platform in the extraction process. To obtain these products that we, or industrial users, need, the crude must be separated by the oil refining. In this operation, a chemical process uses some of the fractions to make others. You can change one fraction into another by one of three methods: breaking large hydrocarbons into smaller pieces (cracking), combining smaller pieces to make larger ones (unification), rearranging various pieces to make desired hydrocarbons (alteration). The refineries must also treat the fractions to remove impurities and combine the various fractions (processed, unprocessed) into mixtures to make desired products. After transformation, theses products will be part of our daily life as Petroleum gas, Naphtha, Gasoline, Kerosene, Gas oil or Diesel distillate, Lubricating oil, Heavy gas or Fuel oil and the Residuals (coke, asphalt, tar, waxes). Also they will be primary source for Petrochemical Plants where they will be transformed in palstics, syntehitcs fibres and other products by ethane cracker, polypropylene, polyethylene processes. Maximise your operating costs Going along with this complex refining process requires huge spaces, tremendous amount of energy and accurate process control. In addition, environment concerns are more and more demanding. The European standards concerning sulphur emission into the atmosphere are very severe, even more so since the 1st of January 2005: the refiners will have several years to bring their plants into conformity, that is to say to rethink and redesign their desulphurisation units to lower even further the sulphur content of fuels. And this is one of the most difficult challenges for refineries: lowering the sulphur, to increase the product quality and reduce the environmental impact. Another issue is the cost of these heavy processes, which lead the refineries owners to constantly search for savings and better performances, along with the ability to adjust their production to the supply and demand balance. At this heavy stage of processing, Schneider Electric helps them to make the most of their energies, providing secured and safe solutions to boost their performances while preserving the planet, maximizing their operating costs. 2,000 gas processing units all over the world Liquefied Natural Gas (LNG) is natural gas (primarily methane, CH4) that is stored and transported in liquid form at atmospheric pressure at a temperature of 260 F. The liquefication process involves removal of certain components, such as dust, helium, water, and heavy hydrocarbons, which could cause difficulty downstream. 19

20 Refineries Integral Security Solution for people safety and secure your assets Energy Management and Control More production with less energy losses and mastering expenses: Schneider Electric recommends purpose-designed solutions to assure energy reliability and availability improving process overall performance and reduce operating costs without compromising environmental concerns or safety. Thanks to our expertise in energy management, we provide a user friendly performing Energy Management and Control Solution, open, scalable and extendable supported by: > End to End engineering from studies to customer autonomy > Energy Management architecture compliant IEC61850: from HV, MV, LV secure power to generation, communication and control devices (RTU, network devices, soft starters, VSD, ipmcc, ) > Safe electrical evolution and maintenance with advanced electrical network modelling > High level of reliability and fast recovery with integrated fast load shedding features > Secured and fast decision process through online simulation and built-in training. We can thus recommend purpose-designed solutions to: > Avoid downtime > Reduce time to repair > Cut time between failures > Maintaining high level of process productivity increasing life of equipment. That means reduce the capital spending and operating costs with reliable energy supply and control even in the hazards areas. Solutions from design to installation, electrical houses, arc resistant equipments integrated to our energy management system assuring reliability and safety. Our experts are trained to improve energy efficiency in large sites and conduct energy quality studies, electrical system optimization and solutions to provide long life to the equipment and assets: downtime and commissioning time reduction, load flow and voltage profile studies, short circuit calculations and protection analysis. In the downstream large sites where the risks are constant, investment and people must be secured. We bring cost-effective solution to prevent against any damages toward the integrity of the production system, environment and assets. Protection against intrusions, terrorism, theft, leakages, and secure fluids containments, to avoid potential injuries either due to human errors and bad operations. Our security experts can provide our Integral Security Solution an open, performing and integrated security solution from video monitoring to access control, intrusion detection and CCTV system: > End to end engineering feasibility studies for security > High performance CCTV integrating specialized cameras applications like ; explosion-proof & Thermal cameras > Integrated plant-wide security perimeter, gate, parking, process Control flare and process monitoring > Hazardous area coverage for worker safety, and mustering in emergencies A performing solution integrating in one unique system: > Access control > CCTV including hazardous areas monitoring > Intrusion access control in hazard areas with image integration > Total right access control in the site > Image treatment alarms for process (leakage) > Under vehicle surveillance > Badge tracking multi tag identification > Real time fire system monitoring, fault detection alarm & intelligent response > Battery & UPS, emergency Generator real time monitoring & alarm > Open integrations to other capabilities, like gate barriers and road blockers > Recording all the events in the plant

21 Schneider Electric won the international project for the petrochemical complex of Borouge 2, Abu Dhabi (UAE) For this new ethane cracker and polyolefin complex, Schneider Electric will provide a competitive and high performance solution to answer the customer needs as high availability and reliable electrical system for non-stop production, secured power for critical process and people & assets safety. 720 refineries, 700 petrochemicals plants operating in the world 21

22 A complete range of dedicated services Helping you obtain the best from your teams and installations Project management Looking for commitment on our part for your modernisation projects and new plants? You can count on the experience and involvement of our teams and the support of our partners. Using the specific tools we have developed (engineering and design software, migration tools and dedicated libraries), production shutdowns are restricted to the minimum. We help you improve the plant performance, proposing solutions for the modernization of your current control and electrical distribution systems and providing solutions for your new installations. And we can provide longer term support by: > Handling design and deployment of a standardised solution and tools on a project that can be applied in other sites, > Associating maintenance of the installed base with planned modernisation. Advice and expertise Need a new method, or skills on a point considered particularly important? Our experts and consultants offer to help you analyse what exists and to define and deploy specific solutions. For operation In operations or preventive maintenance, our tools and methods enable you to access to accurate diagnostics from our systems: electrical distribution equipment, Intelligent Power & Motor Control Centres, communication networks, speed drives, process control systems. In case of intervention, a detailed and commented report is provided following our technical visit. For modernisation and new projects > At pre-project, our consultants help you assess opportunities, define solutions, estimate budgets and propose deployment techniques. With diagnostics, recommendations and results of feasibility studies, you validate and secure your project. > For project steering, our experts provide support in preparing specification studies (software standardisation, architecture diagrams, etc.), assistance on solution deployment and results checking. 350 Oil & Gas specialists, 2,500 Services & Projects engineers, 3 global engineering centers located in Shangai (China), Grenoble (France), Houston (USA) 22

23 Maintenance contracts Do you count on long-term reliability and performance of your installations? Let s build together your custom services contract. Services pack or made-to-measure: > Telephone support for priority access to our experts centre, > Web access to benefit from latest version software, > Stock of our branded replacement parts on your installations or in our warehouses, > Assurance of on-site assistance within a guaranteed time. We help you anticipate technical risks and perform essential modernizations by taking account of equipment obsolescence. It avoids penalizing production shutdowns. You control maintenance costs by optimised replacement parts stock management. Replacement parts and repairs Does your competitiveness depend on your reactivity to breakdowns and malfunctions? We can help you limit downtime periods. From our stock we can supply you with tested and certified replacement parts compatible with your installed equipment. By contract you can stock on your installations replacement parts which remain as our remote stock until be effectively used. Finally, you have also available a strong distribution channel network, present worldwide, that opens to you another access point to our products. Training Does safety of your operation and plant performance depend on constant adaptation of the skills of your personnel? We can help you: Identify your training requirements by systematic analysis of levels and functions of your teams, propose training modules covering your installed automation equipment, follow up acquisitions by ongoing training, offer training modules designed to suit your timing and locations. You have available over 50 training centres with high technology learning tools, professional trainers expert in both industry and teaching, standard or customised courses on-site or on our installations. Our offers help you to > Anticipate risks > Improve your performance > Keep control of your investments 23

24 Make the most of your energy Schneider Electric Industries SAS Head Office 35, rue Joseph Monier F Rueil-Malmaison FRANCE Due to evolution of standards and equipment, characteristics indicated in texts and images in this document are binding only after confirmation by our departments. Design: pemaco Photos: Getty Images, The Image Bank/Luis Castaneda Inc, Digital Vision/Hans-Peter Merten, Photodisc/Andrew Ward-Kim Steele, Corbis/Keith Wood-Mark Karrass-Comstock-Larry Georges, BananaStock/GraphicObsession, Fotolia/X-Codreanu Mihal-Mathias Berendt-Jon Casey, Steve Lovegrove Tecmaxx Tecnologia em Automação Ltda. (Brazil) Eduardo Mizuno, Schneider Electric. Print: DIACED EN ART /2009