Awt Overview
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1. The document provides an overview of the Automatic Well Test (AWT) facilities at Caltex Pacific Indonesia including the number of test stations, controllers, software, and typical process flow. 2. It describes the 10 step AWT process from idle to data collection including purging, gauging, closing valves, and potential failure points. 3. The AWT system aims to automatically select well candidates, execute tests according to parameters, and collect field data to evaluate results.
Awt Overview
- 1. AWT Overview Duri Automatic Well Test PT. Caltex Pacific Indonesia Sukis Haryanto
- 2. DURI WELL TEST FACILITIES 1 8 13 11 10 12 9 7 2 3 4 5 6 3803 69 29 Total 280 7 1 11 400 8 4 10 608 8 4 9 347 6 2 8 600 10 5 7 424 8 4 6 624 12 4 5 520 10 5 4 # Well Address # of Train # of Quadrant Area
- 3. Resources Controllers GE Fanuc, GE-9030 Areas 4,5,6,9 Allen Bradley, PLC5/30 Areas 7,8 ABB Bailey
- 4. Software 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
- 5. Field Automation Component CPI NETWORK DURI CONTROL ROOM COMPUTER ROOM DATASERVER OPERATOR REMOTE VIEWER CONTROLLER Comm Media Actuator Water Cut Probe Control Switch Etc. Communication Media Fiber Optic Wireless LAN Dial up Microwave Radio IDDRINTSCADA01 IDDRIUXDB1 DREAMS MMI & Printer Operator Station
- 6. AWT Process Diagram WELL TEST PRIORITY CRITERIA: 1. WELL WORKED 2. % DIFFERENCE OF BFPD WITH 5 PREV. TESTS. 3. % DIFFERENCE OF CUT WITH 2 PREV TEST 3. LAST TEST DATE 4. SURFACE EQUIPMENT CHANGES DURI-FA DATA COLLECTION PRIORITY WELL WORK SE CHANGES TEST RESULTS ENGINEERING - DATA ANALYSIS OPERATION - MONITOR AND - CONTROL TEST STATION - OVERRIDE PRIORIY DREAMS WTCP SENSOR
- 7. AWT Typical Piping PUMPING UNIT TO CGS TO SLOP OIL FOULED HEADER MICROMOTION CUT PROBE NOC GAUGE PUMP GAUGE SEPARATOR GAUGE TRAIN 1 TEST LINE 1 TEST LINE 2 MANIFOLD A/B CUT PROBE NOC PUMP GAUGE GAUGE SEPARATOR GAUGE TRAIN 2 TEST LINE 1 TEST LINE 2 MANIFOLD C CUT PROBE NOC GAUGE PUMP GAUGE SEPARATOR GAUGE TRAIN 3 TEST LINE 1 TEST LINE 2 MANIFOLD D F2 F1 F2 F1 F2 F1 MICROMOTION MICROMOTION LSLL LSL LSH LAH F3 LSL LSH LSLL LSL LAH LSLL LSL LSH LAH F3 F3 BPCV BPCV BPCV
- 8. 10 Steps of Automatic Well Test Idle Sending Parameter Purging I Positioning valve Flushing Gauging Closing valve Purging II Sand jet valve open Sand jet pump on Well test process is executed by PLC but it is started by MMI.
- 9. Automatic Well Test Process Start Duri-FA Server Well Test Candidate Selection Process(1) Well Test Candidates Operator 2 Abort Record in Gauging.txt Test Train On ? Yes No 3 Abort Test? Purge I Gauging Tank Wait current Process Yes No System Idle? No Yes 7/8 Level below LAH Before Max Limit of Purging time? Yes No 18 Well Valve On? No Abort and Record in Gauging.txt 5 Yes Open Configuration Valve To Test Line Success? Yes No 11 Open Well Valve to Test Line Flush tank till reach time period and pump fluid till below LSL Success? Yes No 11 Abort Yes No Fluid Level Reach LSH? Wait Start Pump Pump Rate GT Min Rate? Yes No 12 Totalize Oil & Wtr Calculate WC Average Temp. Any Reading on NOC? Yes No 17 Fluid Level Reach LSL ? Yes No Shut off Pump Reach Gauging Period? Yes No Close valves & start pump Total Volume Calculate WC Avg Temp Test Line ON ? Yes No 4 Fluid Level Under LAH ? Yes No 10 21 Sending Parameter (1 minute) Fill Gauging Tank Fluid Level Reach LSL before Time limit No 20 BPCV pressure Switch Closed ? Yes No 22 Success? Yes Abort No 13 No under no choice indicate status code
- 10. Field Data Collection PLC Flow Sensor Water Cut Sensor Flow Transmitter In Out In Out Pulse (Total Oil) Current (4 - 20 mA) Pump Rate Current (4 - 20 mA) Pump Rate Pulse (Total Oil) Net Oil Computer
- 11. Completion Status Automatically Initiated Manually Initiated Aborted Because The Test Train Was Off-Line Aborted Because The Test Line/ Configuration-Valve Was Off-Line Aborted Because The Well/ Control-Valve Was Off-Line Cannot Read Temperature Meter Stopped By Operator Aborted By Operator Aborted Due To Priority Leak Test Aborted Due To High Fluid Level In Separator Aborted Due To Valve Error Aborted 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 Shutdown Aborted Due To Ac Power For Field Devices Failure Aborted Due To Ac Power For Controller Voltage Failure Aborted Due To Error Reading Instruments Aborted Because The Wtc Was Unable To Purge The Separator Aborted Due To High Production Aborted Due To No Flow Into Separator Normally Completed Aborted Due To Bpcv Fail 0 = No 1 = Yes
- 12. Automatic Well Test Data Flow 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. Gauging Process Well Test Results Loading Process Selection Process Acceptable Tests Rejected Tests Gauge_Result Table Transfer Process Evaluation Process Dreams
- 13. Major 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
- 15. Idle 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.
- 16. Sending 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
- 17. Purging 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
- 18. Positioning 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
- 19. Flushing 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)
- 20. Gauging 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.
- 21. Closing 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
- 22. Purging 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
- 23. Sand 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
- 24. Sand Jet Pump On Pumping fluid from tank bottom
- 25. Data Acquisition Process Alat-alat Lapangan PLC Aplikasi Wonderware Aplikasi Layanan I/O Pemberi sinyal dan pelaksana perintah dari PLC Pengatur dan pemberi perintah kepada peralatan di lapangan Mengenalkan sinyal PLC kepada aplikasi Wonderware dan sebaliknya Memerintah PLC, menerima sinyal dari PLC, mengolah menterjemahkan dan mengvisualisasikan di Layar PC serta menyimpan informasi dalam workstation.
- 26. Skill Requirement for SCADA Maintenance 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
- 27. Well Test Controller ENG Alarm Printer MMI & Printer Controller Well Test Station Note : Area 1 thru 3 Manual Well Test Area 4 thru 9 Automatic Well Test ( Communicate to Radio & Micro Wave )