Case Studies en Oil-And-gas

8/2/2019 Case Studies en Oil-And-gas

1/12www.hirschmann.com 53

Oil / Gas

The Northwest Region of So Paulo State, inthe South of Brasil, is recognized as a leader inagricultural and related industries. In addition toorange juice production, this region has been alsoa worldwide leader in the production of sugarand alcohol. The additional energy demand ismet through Thermoelectric Power Plants which

stimulate demand for natural gas. A 575 kmpipeline links this region with the main Bolivia-Brasil Gas Pipeline. Gas network management isrealized by a High Speed Industrial Backbone.


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Project details

A high level of technical integration andco-ordination is required for the successfuldeployment of this complex system. A Local AreaNetwork utilizing TCP/IP Standard serves therequirements.

Project parameters

Customer: Gas Brasiliano Distribuidora Concessionria de Gs Canalizado reaNoroeste.Contract Period: Under developmentContract Value: US$ 900.000Key Data: 575 km distribution network Redundant Server SCADA System 24 Remote Terminal Units (RTU) Alarm Announcing Server Frame Relay and Fiber Optic Communication Solar Panels Power Supply

High Speed Industrial Standard Backbone RTU Ethernet TCP/IP standard protocol

Requirements

Custom-built SCADA functionalities for gasnetwork management

Visual picture of system operationProcess intervention through a graphic userinterface (GUI) protocolUser friendly, SCADA and automatedmaintenance tools.Integration Performance

SolutionNetwork topology: Gas distribution line to different locations Singlemode connections up to 60 km Connection of the gas distribution area to theCentral Station with frame relay

Devices used: Hirschmann Rail Switches RS2-FX-SM/FX-SM,

RS2-FX-SM/FX-LH, RS2-FX- LH/FX-LH Hirschmann Rail Transceiver RT2-TX/FX-SM Hirschmann Modular Gigabit Ethernet

Switch MACH 3000 in Central Station24 stations along the new pipeline to receivegas from the GASBOL pipeline, maintainflow rates, measure and control the physiccharacteristics of the gasOperator Control Center in Araraquara CityMonitoring Center located in Araatubaprovides the regional team data and toolsRedundant Real Time and Historical Data Server,Operator Stations and Alarm ServerClient-Server and SQL standard data base tointegrate the system with the Gas BrasilianoCorporate SystemSupervisory Control SoftwarePublic Frame Relay Technology

Fibre optic cables (quasi-star configuration)

Ethernet 100 mbpsTelecommunication system redundancyLow power consumption RTUs for controllingand monitoring the stations and to managecommunication to flow computers or evenchromatographers.Solar Panels and large capacity batteriesAlarm Announcing Server, automatically makescalls to the maintenance team

Why Hirschmann?

Redundancy concept with HIPER-Ring

Homogeneous product familyIndustrial standard products

www.hirschmann.com CS 027-02-0205



Oil / Gas

Crude oil and natural gas reserves make Kasachstanan important country for the global energymarket. A quick look at a map and it becomesclear that lack of access to the sea makespipeline systems essential for the transportationof crude oil and natural gases. KTO, the state oil

transportation association in Kasachstan, equips itspipeline network (approx. 6000 km) with modernautomation equipment and technology.


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Project details

The aim of the project is to significantly increasethe pipeline flow rate while at the same timeimproving the reliability of the system. The majorenvironmental issues and the necessity for controlof the entire installation (pipeline and automationequipment) require a modern and reliablecommunication technology over long distances.After all, the operators must be able to identify theexact location of potential leaks quickly and assessunexpected reduction in performance.The devices must be easy to use so operatingpersonnel can use it after just a short trainingperiod.

Project parameters

Ethernet technology has entered into theautomation field and enables communicationsurroundings, which are cost-effective intheir implementation. As in many industrial

applications, a secure transfer of data overlong distances is also essential for the pipelineinstallations in Kasachstan.

Requirements

The pipeline network covers around 6000 km.The system covers several pump stations.The oil pressure is kept at approx. 50 bar (thanksto scaleable control and surveillance technologyfrom ABB).The stations must also give informationregarding potential leaks.

Solution

The mid-sized networks in the pump stationsare equipped with cost-effective RS2-FX/FX Ethernet switches from Hirschmann in aredundant configuration, (mounted on DINrails). A LED on the front of the switch showsthe faults. The first remote diagnostics ispossible of a web server, which is served by thedevice.The Hirschmann-HiOPC-Software serves as agateway and makes the SNMP data available inOPC format.Switches from the series MS-3124-4 have alsobeen installedThe switches are connected with the help of aLWL-ring topology

Why Hirschmann?

Hirschmann offers a reliable and high-performance network based on redundant

Ethernet technology, fulfilling all kinds ofdemands. The special environmental conditionsrequire devices, suitable for operation in harshenvironmental temperatures. The patentedHIPER ring technology from Hirschmann enablesextremely reliable and stable networks whilelowering the installation requirements and costs.

www.hirschmann.com CS 029-02-0705This case study was compiled in cooperation with ABB AG .



place on land and in shallow

coastal waters but also on the

Oil / Gas

The drilling platforms must keep their positionaccurate to a few metres with engine powerso that the boring rods dont break. Thehighest demands are placed on the operationalreliability of the dynamic position controlbecause should the platform drift off there isthe danger of great environmental damage

and downtime. Converteam has designeda control system for the Transocean SedcoForex platforms that meet the highest safetydemands. As well as other safety precautionsthe control components are therefore designedwith multiple redundancy and networked withfail safe fiber optic cables.


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Project details

Oil exploration platforms can tap into depositsunder the sea down to 3,500m deep. In shallowwaters such as the Gulf of Mexico the platformsare firmly anchored to the sea bed. Oil explorationplatforms suitable for the high seas must keeptheir position above the bore hole with enginepower in spite of the wind and currents. Theirposition is recorded by satellite with GPS andby sonar buoys on the sea bed. Their position ismaintained by powerful electromotors on thefour corners of the platform. These can revolvethrough 360 degrees. The dynamic positionmaintenance control system and the associatedfield bus network must meet high real time andreliability requirements. Converteam opted for theFIP field bus protocol for the Transocean SedcoForex express class platforms and networked thecontrol components with Hirschmanns fiber opticcable repeaters.

Project parametersPositioning accuracy better than 5 mMaximum ocean current 3.5 knotsMaximum wind speed 60 knotsMaximum wave height 9 mInstalled engine rating 4 * 7MWMaximum water depth 3500m

Requirements

Real time enabled bus systemError monitoring and alarm indicationNo single point of failureError tolerant control system

Solution

Complete optical networkingWorldFIP field bus systemFour hierarchically structured field bus ringsDual design, multiple meshed ring in dynamicpositioning systemConstant status monitoring in dual monitorsystems40 OZD FIP G3 T LWL repeaters per platformLWL cable with multimode 62.5 / 125m fibers

Maximum cable length 300m

Why Hirschmann?

WorldFIP field bus has very high real time

capability

Hirschmann LWL repeaters ring capability

Very fast switch time should the ring fail

Use of error contact in the platforms SCADA

system.

Quality standard confirmed by Survey

www.hirschmann.com CS 040-02-1105This case study was compiled in cooperation with Converteam.



plant in the world.

Oil / Gas

Here, the Schwelgern GmbH coking company

belonging to the ThyssenKrupp Steel AG

produces an annual 2.5 million tons of coke

from coal for the neighboring large blast

furnaces. The transformation takes place in a

total of 140 of the worlds largest coke furnaces

with a capacity of almost 80 tons of coal each.

In addition to coke, gas, tar and other carbon

materials are also produced from the coal. ABB

is responsible for the automation and uses

Hirschmann field bus and Ethernet components

for the automation.

ThyssenKruppSteel


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Project details

For the automation of the coking plant, ABB

chose a consistent networking of the system.

The continuous data flow stretches from the

control level to every single sensor. The system

therefore defines the current state of the art

with its size and the implemented environmental

equipment. The degree of automation allows a

fully automatic, unmanned furnace operation.

The data networks for PROFIBUS and Ethernet

signals are designed redundantly for the necessary

operational reliability and critical connections are

made by fiber optic cables.

Project parameters

Annual amount 2.5 million tons of coke

Produce coke gas flow 155,000 m3/h

140 coke furnaces with 93m3 useful volume

each

135 pressure processes / day

approx. 100,000 data signals

approx. 5,000 measuring points

approx. 1,700 PROFIBUS users

Requirements

Homogeneous data networking

Gigabit Ethernet in the backbone

Redundant Ethernet on the control level

Redundant FOC- PROFIBUS networking on the

process level

Solution

Redundant rings on all levels

Structured networking with PROFIBUS DP, Fast

and Gigabit Ethernet

FOC cabling for EMC safety

250 OZD Profi

22 RS 2 FX/FX

18 GES-24 FX

1 GRS 1403

2 MACH 3005

Why Hirschmann?

Universal product family

Redundant design with fast HIPER rings

Industry proven products




There is constant pressure in the

stations.

Oil / Gas

The central Asian country of Kazakhstan is the

ninth-largest country in the world. It possesses

enormous crude oil and natural gas supplies.

Nearly 160 oil and gas deposits have been

discovered so far. Thus Kazakhstan is one of

the most important countries for the future

world energy market. Foreign investment today

are creating a booming crude oil industry that

is the driving force for the economic growth

of the country. Without a sea port, export is

only possible using pipelines. The national oil

transport company KazTransOil modernized its

6000 km long pipeline network with the most

modern control technology. The communication

technology does not only increase the flow

rate and the reliability, but it also detects

and localizes leaks from extensive networks

due to the integrated monitoring technology.

Environmental damage can be avoided in this

way, or at least quickly contained.


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HIRSCHMANN

HIRSCHMANN

HIRSCHMANN

HIRSCHMANN

HIRSCHMANN

HIRSCHMANN

ETHERNET

HIPER-Ring

redundanter

PROFIBUS-Ring

Steuerung

I/O

I/O

zum Weitverkehrsnetz

Project details

ABB drafted a financing model of the 43 million

$US project for the general contractor and

was the main contractor for the entire control

technology. The oil in the pipeline is at 50 bar

pressure in order to ensure high and uniform flow.

Pump stations are needed at regular intervals for

this. At the field level, reliability is also important.

Therefore, the controls are connected to the

sensors and servo motors with optical profibus

rings. The higher-level data network in the pump

stations is realized with redundant Ethernet

rings. The entire station data is routed from

the individual pump stations, via the extensive

telecommunication networks, to a central control

room. In the individual pump stations, control and

monitoring technology from ABB is used.

All components important for operation are

designed in duplicate, and work with distributed

intelligence in multiple controller pairs networked

via profibus and Ethernet. Constant monitoring

of pressure and flow makes it possible to detectand localize leaks in the pipeline train. The

operating and monitoring system warns the

system personnel when there is a malfunction, so

that the appropriate measures can be introduced.

A powerful, and reliably-working profibus and

Ethernet network, even under adverse storm

conditions, is the basis for the entire control and

monitoring functions and enables future

expansion through modern technology.

Project parameters

More than 6400 km pipeline network

The oil pressure is kept at approx. 50 bar

(thanks to scalable ABB control and monitoring

technology)

50 000 measured data

1200 profibus nodes

Requirements

High level of reliability

Redundant ring topologies

Solution

Ethernet rings between the individual

controllers

PROFIBUS rings in the field level

400 OZD Profi 12M

380 RS2-FX/FX

Why Hirschmann?

Fiber-optic based profibus due to EMV

strengthIndustrial standard mechanism

High level of reliability




Oil / Gas

Production has recently started at two new

oilfields 50km southwest of Abu Dhabi City,

Rumaitha in the countries interior and Al

Dabbiya on the coast. The daily production

capacity of the fields is about 100,000 barrels.

The facilities for producing, storing and

metering the crude oil have been in operation

since late 2005. Operating safety is paramount

here, so the process control system has been

designed with full redundancy, and data is

transmitted between the controllers and the

remote I/O stations via fail-safe, redundant

optical fibers. The danger of explosion that is

inherent in such facilities presents a particular

challenge. This challenge must be met with ATEX

approved devices that are also capable of

withstanding high ambient temperatures.


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Project details

The process control system designed as a

redundant sysstem to specifically meet the

customers demand for high process data

availability. The process control units constructed

by Honeywell provide a primary and a secondary

Profibus DP interface with the remote I/O stations.

HART information is recorded via an independent

service bus using an RS 485 interface. Optical

cables and redundant optical rings ensure an

exceptionally high level of operating safety. The

cabinets installed in explosion protection zone 2

include devices for properly isolating the

intrinsically safe signals that are primarily used

here for transmitting to zone 1 and zone 0. The

power supplies for the remote I/O stations are

designed redundantly. The cabinets have been

engineered to prevent heat accumulation and they

are also equipped with solar protection means.

Otherwise, it would not be possible to keep the

electronic components in the cabinet sufficientlycool in desert conditions.

Project parameters

Profibus DP and HART communication

15 km transmission length

2600 process signals

72 remote I/O stations

176 OZD Profi 12M G12

26 OZD Profi 12M G12-1300

88 OZD 485 G12

13 OZD 485 G12-1300

Requirements

High availability of the process control system.

85C solar temperature

52C air temperature

95% maximum air humidity

Explosion protection zones 2 and 1

Solution

Redundant control stations with two Profibus

interfaces

Redundant communication via optical Profibus

DP rings

Communication with HART Management

System

Switch cabinet designed for high operating

temperature

Devices ATEX-approved

Why Hirschmann?

Fiber optic converter for Profibus DP

Fiber optic converter for HART via RS 485

Designs for long and medium segments

Redundancy with optical rings

ATEX approvals received

www hirschmann com CS 068 02 0607

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Case Studies en Oil-And-gas