Rockwell - Automation - ConnectedProduction - Repsol Apr2018

ConnectedProduction
Realizing benefits of Industry 4.0 and IIoT

Jose Manuel Pozo
Oil & Gas Manager
Thony Brito
Regional Sales Manager DOF, Rockwell Automation
PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 1

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Agenda
1. RA experience in Digital Oilfields

2. Data quality through ConnectedProduction
3. Our vision of a Connected Enterprise
4. Definitions and architecture
5. Data Acquisition Enablers
6. Demo
7. Embedded Intelligence
8. Videos
9. Case Studies
10. Coming soon.. Cloud Analytics

RA DOF EMEA – Current Position
• 300+ Wells Monitored with
• 5,000+ Wells automated in PDO Oman
TotalAccess software
• ESP, GL, Steam Injection, LNG
• ESP Curves used during 6 years
• Developed customized NOC
• Umm Al Dalq and Satah

• 50+ ESPs Solutions Well Surveillance and
automation
shutdown panels in ADCO
• Zirku Island disposal wells
• Wireless Wellhead Monitoring
• 1000+/- Wells with Real Time Monitoring, Nigeria

SCADA, Historian • 300 Well Shell
• 44+ North Jurassic Gas Wells • 15+ Wells XOM
• ICSS - Drives • 30+ Wells CVX
• Integrated remote monitoring,

• 150+ Wells – Wireless Monitoring
control and video surveillance
• EDHG Monitoring
pilot

Timely & THE VALUE OF THE Contextualized
Available Data Data
DATA
Reliable & Actionable
Trustworthy Data Data

Digital Oilfield Definitions
The term "digital oilfield" has been used to describe a wide variety of activities, and its definitions
have encompassed an equally wide variety of tools, tasks, and disciplines. All of them attempt to
describe various uses of advanced software and data analysis techniques to improve the
profitability of oil & gas production operations. Frequently recurring digital oilfield themes
include—but are not limited to:
Operational Efficiency – Collaboration, multidiscipline teams Data Integration, Visualization, Smarter Dashboards,
Reservoir, Drilling, Production, Engineering, KPIs Definition and Reporting
15% Cost Reductions Maintenance and Operations, IT, finance
Workflow Automation:
Production Optimization– Optimization Cycles Acceleration from months to To extract new unforeseen
3 to 8% Production Increases days, hours values through Big Data & Analytics
Standardization, best practice implementation
Reservoir recovery increase–

More Automation is required due to Skill Gap Decision Support
Up to 3%
The Digital Transformation Journey
Secure Pathway from Production Data to Actionable Intelligence
ANALYTICS OPTIMIZATION
DATA COLLECTION & REASONING
& AGGREGATION
IMPLEMENTATION
ASSESSMENT

Some digitalization challenges
• Real Time, SCADA, DCS
• Multiple databases
Multiple Data Sources • Structured and unstructured data
• Data Manipulation
• 20% to 60% of engineering time

Data Quality Assurance, • Paths - Flow of data from source to consumption point
• Data Contextualization
cleansing • Data Formatting
• Manual, legacy
• Disparate Applications
Workflow Automation • Roles and Governance
• From sampling to n=all, Outcome, Low fidelity, bigger data pool

• Tools and Platform Selections
• Flow of data to Big Data Tools, Algorithm, Correlations,
Big Data, Analytics
• Change Management, from why to what, causation vs. new outcomes
• Resources, Data Scientists, Algorithmists
• Machine Learning/AI
• OT/IT Convergence
Security and mobility • Network Topology/
• On premises vs.cloud
• Mobility

• What is ConnectedProduction™?
• Enabling Technologies
ConnectedProduction™ • Fundamental Solutions

Optimize the Digital Oil Field

An upstream O&G Connected Integration
of field
Enterprise vision data with
surface
ERP
Increased facilities
Rockwell Automation® Analytics and production and provide a
optimization other data
Cloud Wells – Reservoir – Surface corp. User holistic
Network apps Stations
quality view of the
(Microsoft Azure)
plant
Surface
facilities
SCADA – Historians DCS

Data Models – Data Cleansing and Data Management
Manifolds and Natural Flow/ Virtual Gas Reciprocating Electric Submersible

Pipelines Flow/ Net Oil Computer Lift Pumping Pump
What is…
ConnectedProduction™?
Enable
ConnectedProduction provides Oil & Gas Strategic intelligent
producers the secure connectivity, and scalability, Opportunity decision
required to visualize and optimize production from making
the well head to the point of custody transfer.
It is an open, flexible, secure, scalable solution

designed to expand your current architecture, Current Improve
Direction performanc
allowing producers to leverage their current
e
investment…
Resolve
issues with
Expand Your “Data Cube” Historica
l operations &
Footprint functions
Basic Advanced Intelligent Decision

SCADA Systems Making Systems

ConnectedProduction™
On Premise Architecture
Simplex (default), redundant and high availability options available
Industrial Data Center (IDC) E2000
FactoryTalk® VantagePoint EMI server and client
FactoryTalk® View server and client
FactoryTalk® Historian SE
FactoryTalk® ViewPoint Client
OPC Server (KEPWare and/or RSLinx®) Modbus
EtherNet/IP
Logix
Artificial Logix OptiSIS™
Lift (MTU)
Production
Flow RTU Automation AADvance®
Monitoring RTU Production

Well Pad – up to 32 wells Safety
Scalable Architecture
On Premise Architecture (Large)
Simplex (default), redundant and high availability options available
Industrial Data Center (IDC) E2000
FactoryTalk® VantagePoint EMI server and client
FactoryTalk® Historian SE
Pi-to-Pi connector
Industrial Data Center (IDC) E2000 Industrial Data Center (IDC) E2000
FactoryTalk® VantagePoint EMI Server and Client FactoryTalk® VantagePoint EMI Server and Client
FactoryTalk® View Server and Client FactoryTalk® View Server and Client
FactoryTalk® H FactoryTalk® Historian SE FactoryTalk® H FactoryTalk® Historian SE
FactoryTalk® ViewPoint Client FactoryTalk® ViewPoint Client
1 n OPC Server (KEPWare and/or RSLinx®)
OPC Server (KEPWare and/or RSLinx®)
EtherNet/IP Asset EtherNet/IP Asset

Asset Asset
Modbus Asset Modbus Asset
On-Premise Architecture (up to 500 assets) On-Premise Architecture (up to 500 assets)
Cloud Architecture
Rockwell Automation® Cloud

(Microsoft Azure)
Gateway Logix
Artificial
Gateway
Logix OptiSIS™
Lift Gateway
Gateway
Gateway
(MTU)
Flow Production
RTU Automation AADvance®
Gateway
Gateway
Monitoring RTU
Production
Well Pad – up to 30 assets Gateway Gateway Safety
Creating a data model for each production asset
Instrumentation DHG Choke

and Data Acquisition Surface
Instruments
WHCP
Safety System
Shutdown SIL Syst.
Chemical Inj.
Integrity System
Cathodic Protection
MPFM Data
Well Well Test
Skids - Portable
Models
Motor Controller –
ALS Systems Switchboard
Optimization Pumps - Drives
Reservoir and Surface

Analytic
Network Applications
Optimization
Asset Management
Maintenance System

Data contextualization and events - MQTT
Messaging subscription
services – MQTT
Generate events and
interfaces.
Enables auto-discovery
Relates data with events:
Choke sizes changes
Well Test issues
Low Flow condition
High pressure
Security or safety
related events.
Enables back-filling for data
comm. Losses.
Typical System Architecture
Combined System Architecture for Phase 1a & Phase 1b

Enabling Technologies
• Wireless Instrumentation
• Intelligent RTUs with apps
• Wellhead Safety Solutions

Asset Added Flow
Consume
“Asset Added”
Message
Asset
Receives config &

Power On
starts data publishing
Azure IoT hub MQTT Protocol Publish TagMap

Secure encrypted transmission config to Asset
Guaranteed Delivery
ConnectedProduction
IoT Hub
Display notification in
browser to confirm Asset
Create the Well in Configure polling engine,
Receives Displays notification in creation
ConnectedProductio configure historian, start data
“Discovery” browser showing Link to
n logging, configure
Message Add Asset wizard
visualization Send “Asset Added” msg to
Production Operations Software
CP API handles orchestration of
Push notification to clients
configuration tasks. Creates
logical model of asset. Messaging Queue
PUBLIC
ConnectedProduction™ • Embedded Intelligence
• Hardware
• Software

Defining Data Through Scalable Assets and Data Models
Scalable Computing
(Control, Edge, Cloud)
Information Management 3rd Party Connectivity

& Analytics
Mobility & Intelligent Assets Secure Network

Visualization Infrastructure
INTELLIGENT ASSETS ARE SELF-AWARE & SYSTEM AWARE
PUBLIC
Intelligent Assets – IIoT Enabled devices
Big data and Analytics
Intelligent Applications
Workflows & optimization
SCADA-Historians packages Local Cloud
Auto-discovery
Self Diagnostics
Process Diagnostics and

Alarms
Process Optimization through

embedded algorithms
Virtual Flow
Wet Gas
Rod pump control

Natural Flow/ Virtual Gas Reciprocating Electric Submersible
Net Oil Computer Flow/ Net Oil Computer Lift Pumping Pump
Analytics for Devices

Sherlock

Embedded Intelligence @ controllers
Optilift NF with Well Curves and

Operating Point
Virtual Flow @ Controller

Black Oil & Wet Gas
iNOC – Intelligent Net Oil Computer &

Well Test Controller ( up to 20 wells)
Rod Pump Controller &

RPC with drive
Pump off, fillage
Well Pad Controller

Multiple ALS Controller in well pad
16 & 32 wells configuration

Embedded Intelligence @ software
ESP Early Warning Alarms
Virtual Flow Calculation – Black Oil
ESP & PCPs

Pump Performance Curves
Well Test Control and Intelligent Alarms
Beam Pump Diagnostics

& Optimization
Model Predictive Control
Embedded workflow engine and

Native portal to AVOCET/OLGA
Embedded workflows to link to any

Third party analytics engine

PavilionMPC Solution Development
Process test Modeling Configure Simulate Online KPI

WE HAVE A SOLUTION FOR THAT.
Advance Analytics on the cloud

Digital Oilfield Journey
Assessment
Optimization and Management
Tools
Remote Monitoring Smart Device Applications

and Control, Smart
Applications Optilift – iNOC – Project Sherlock
Feedback
CP embedded analytics
Telecommunication Pump curves, Fuzzy Logic,
and Network Design, Beam pump diagnostics
Embedded Security
Asset Management Systems

Visualization,
Life Cycle Support
Alarms, Reporting,
Historians Pavilion –
Advanced Process Control
Optimization Engines
(Modeling, Big Data
Third party – Analyticis
Tools, AI ) Schlumberger – PETEX – WFT -Hal

ConnectedProduction™ • Case Study
• Remote Wellhead Monitoring

Case Study
Wellhead Remote Monitoring and SCADA System
29
SPDC Operations
SPDC has over 2000 producing wells in the Niger Delta
region of Nigeria.
There are various fields scattered over a wide geographic
area.
None of the wells have any digital monitoring facility
Daily wellhead visits by SPDC to capture well data

Challenge
Wide geographic areas posses significant logistical
challenges for personnel to capture data manually.
Hostility of host communities creates a huge personnel
safety concerns
Fields are scattered in both land and swamps within thick
forest
Difficulty in timely detection of a shut in well leading to
production loss
Huge number of producing wells require an effective real-
time integrated system
31

Solution Architecture
Implementation of cost effective RTU that monitors six
different parameters simultaneously
Monitoring of:
Tubing Head Pressure
Casing Head Pressure
Flowline Pressure, and
Temperature
Wireless network solution that successfully delivers
data in spite of the thick forests and jungles

Value Provided
Reduction of security risk, escort and logistic costs in 30% by reduction
Cost reduction by 20% on each well investment by using battery operated RTUs, two years
battery duration.
Reduction of theft by not requiring solar systems.
Reduction of costs of engineering and radio studies. The design of the radio network was
included in the scope of Rockwell. Pathloss Software was used to design it.
A combination of 400MHz, 900MHz and 2.4GHz Field Wide wireless network.
SCADA System provides Control, Trending and Historical Reporting options
Gathered data integrated into company wide OSI PI system

Installation Pictures- Wireless communication in the jungle

Kuwait Oil Company (KOC)
Digital Oilfield Project
PUBLIC
PUBLIC - 5058-CO900H Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Combined data acquisition and safety
Well Head Location
Features:
Well instrumentation: Pressure, Temp, H2S,
Combustible Gas.
Wellhead Control Panel.
Rockwell
SIL2 and SIL3 Wellhead Safety programmed AADvance PLC
Corrosion monitoring
Automated choke valve control
Wireless video surveillance
Benefits:
No FEED Costs.
F
Reduced project deployment time 25% L
5% production increases
Reduced theft

System Architecture
Hybrid telecomm
Network –
WIMAX & FO
Integrated DOF project, direct link to

AVOCET Workflows
Replica and disaster recovery

available
Defense in depth

KOC ESP, Injection and NF
– 1200+ Sites
Lump Sum Contract, lease over three years.
Five+ different fields, 200+/- wells per fields. Multiple master. ESP Wireless Remote
Seamless aggregation Monitoring/Control
System
Functionality:
Remote Terminal Unit
Remote control and diagnostics, choke size adjustment
Remote start – stop of ESP Wells Wireless GPRS
Wireless Instrumentation, Pressure and Temperature Communication Unit
H2S and GD.

Retrofit of WHCP with solenoid. ESP Variable
Speed Drive (VSD)
Pre-mapped ESP Motor control.
Benefits: Well in Kuwait
Quick deployment – two hours per well
Reduction of Maintenance costs by estimated 15%. (RA maintains).
Zero cost of spares management, 3% reduction costs
Reduced engineering costs, no FEED costs.and timing executed.
RA made detailed engineering as part of contract.
Reduction of pump trip troubleshooting time in 40% from days/weeks
to hours.
95% of telecomm uptime with WIMAX.

Typical system architecture
Hybrid telecomm
Network –
WIMAX & FO
Multiple Masters
Control only in the field
Corporate OPC Gateway –

Feeding multiple apps
3000+ Wireless Transmitters
100+ Solar Panel powered

vMonitor Solution offshore asset
Monitor Up-stream and Down-stream
Pressure points on 24 wells by means of
Wireless Pressure Transmitters based on
long lasting battery
Provide Well Shut Down alarms on
vMonitor TOTALACCESS SCADA Software
Employ GPRS network in field to transmit
data to Client HQ and then distribute over
Client Intranet to field operators and
production team
Local telecomm operator cloud.

PDO Oman – 5000+ Wells
RA vMonitor delivered to PDO
a Digital Oilfield infrastructure
for thousands of wells:
ESPs
Water injection
Gas lift
Gas breakthrough
And facilities
Pipeline stations
LNG plants
Steam injection
Local support and maintenance
team for well equipment and
software

Chevron Nigeria
vMonitor Provided a
wellhead remote
monitoring system for a
variety of producing and
gas-lift wells
Gas Lift Monitoring and
Optimization
End-to-end system
Integration
Survey and design study
for more than 400 wells

ExxonMobil Nigeria
vMonitor deployed for
ExxonMobil wireless
well remote monitoring
system
Pipeline monitoring and
leak detection system
Integration to control
room and operations

ConnectedProduction – Value Proposition
Seamless Connection Delivery Guaranteed IT Infrastructure, Fast Loop Optimization of
from remote facilities QoS virtualization, disaster ALS – embedded analytics,
to decision centers
recovery Smart Cloud - AI
Buffering
Contextualized data – On premises or cloud Virtual Flow Calculations,
/Asynchronous
( MQTT ) Communication ( FT or Azure) (Embedded analytics)
Auto-discovery of Data pre-processing Multiple visualization Native connectivity to PE

Intelligent Assets – (filtering of frozen channels, Analytic engines –
faster commissioning
data, outliers, scaling, Desktop, Mobile Schlumberger (Open APIs)
time. ( Data Maps +
MQTT) etc)
Event Notification Comprehensive audit log
Improved data Embedded Cyber Browser
aggregation – Embedded Wiki
Security Email
Scalability (FT VP)
SMS
Thank You.


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ConnectedProduction

Realizing benefits of Industry 4.0 and IIoT

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 1

1. RA experience in Digital Oilfields

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

• Umm Al Dalq and Satah

• 1000+/- Wells with Real Time Monitoring, Nigeria

• Integrated remote monitoring,

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 4

Reservoir recovery increase–

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 2

• 20% to 60% of engineering time

• From sampling to n=all, Outcome, Low fidelity, bigger data pool

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

ConnectedProduction™ • Fundamental Solutions

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 8

SCADA – Historians DCS

Manifolds and Natural Flow/ Virtual Gas Reciprocating Electric Submersible

It is an open, flexible, secure, scalable solution

Basic Advanced Intelligent Decision

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 8

Monitoring RTU Production

EtherNet/IP Asset EtherNet/IP Asset

Rockwell Automation® Cloud

Instrumentation DHG Choke

Reservoir and Surface

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

Combined System Architecture for Phase 1a & Phase 1b

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

Receives config &

Azure IoT hub MQTT Protocol Publish TagMap

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 20

Information Management 3rd Party Connectivity

Mobility & Intelligent Assets Secure Network

INTELLIGENT ASSETS ARE SELF-AWARE & SYSTEM AWARE

Process Diagnostics and

Process Optimization through

Rod pump control

Analytics for Devices

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

Optilift NF with Well Curves and

Virtual Flow @ Controller

iNOC – Intelligent Net Oil Computer &

Rod Pump Controller &

Well Pad Controller

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

ESP Early Warning Alarms

Virtual Flow Calculation – Black Oil

ESP & PCPs

Well Test Control and Intelligent Alarms

Beam Pump Diagnostics

Embedded workflow engine and

Embedded workflows to link to any

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

Process test Modeling Configure Simulate Online KPI

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

Remote Monitoring Smart Device Applications

Asset Management Systems

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. 28