REMOTE AUTOMATION SOLUTION FOR OIL & GAS

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Tyrone Mathews
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1 STC GEOSTAR Ltd Office 204, Chulman pr., Naberezhnye Chelny, Russia, ZIP Tel./fax: +7 (8552) , Web: en.gstar.ru REMOTE AUTOMATION SOLUTION FOR OIL & GAS Manufacturer STC GEOSTAR WWW: en.gstar.ru Tel./fax: +7 (8552)

Top level - Data server and s Technologist Operator Network Data server

beam pumping units, progressive cavity pump, electronic submersible pump and

Internet (WWW) Middle level - Controller ARCHITECTURE The low level.

Available to use any analogue and electronic devices.

filling, production rate; -tubing pressure and temperature; -power and current of

Depth level Load RS-485 Pressure Flowmeter Power The middle level.

Controller is provided the routines with gathering information, logging, storing

). Configuring of controller is made by distantly from remote computer, or at the

Desktop client software «GEOSbor» is designed to operate with this database and

Features OILFIELD gathering the data from remote transducers and sensors

demand; optimal watching for critical values of technological process (i.e. for

emergencies; pumping unit parameters calculation; remote control of equipment

2 Top level - Data server and s Technologist Operator Network Data server APPLICATION The automation remote system is designed to monitor and control the remote devices and equipment. The system gathers data from remote oil and gas wells through sensors and prepare these data to optimize production. Generally the automation system is used for oi and gas wells equipped with the beam pumping units, progressive cavity pump, electronic submersible pump and water injection system. Internet (WWW) Middle level - Controller ARCHITECTURE The low level. This is level of the primary transducers and sensors to measure the data in the control points. The transducers are connected on RS-485 interface and used Modbus RTU protocol. Available to use any analogue and electronic devices. Data to register: -depth level and casing pressure; -dynamometer card, pump filling, production rate; -tubing pressure and temperature; -power and current of drive; -flow data. Depth level Load RS-485 Pressure Flowmeter Power The middle level. This level is organized by programmable controller under OS Linux. Controller is provided the routines with gathering information, logging, storing to the database, and also make the control action for equipment (i.e. pump, drive and etc.). Configuring of controller is made by distantly from remote computer, or at the site through Wi-Fi connection from notebook, PC-tablet or smartphone. Low level - Transducers Top level. This level is the server with database of registered measurements. Desktop client software «GEOSbor» is designed to operate with this database and prepare the data. Features OILFIELD gathering the data from remote transducers and sensors monitoring the remote objects with the predefined interval or on operator's demand; optimal watching for critical values of technological process (i.e. for oil depth level or pump fillage); recognition and prediction of failures and emergencies; pumping unit parameters calculation; remote control of equipment (pump on/off/ speed change); optimization of operation of pump equipment for best performance; wide range of alarms to limit damage from possible failures; forecast for possible repair and maintenance; support for sensors of other manufacturer; easy set-up and maintenance; remote configuration of controller; logging of registered data, user accesses and events; powerful reports, graph tenders, table reports. Oilwell Controller Level meter Load meter Pressure gauge Flow meter ENTERPRISE SERVER Database Technologist Dispatcher Operator GSM modem Drive Control Station SMS Data GSM modem Internet storage

3 SUPPLY SET GS-AMTU AUGPS-112 GS-PU-102 UIK SOFTWARE DDS-102 GS-DT-102 GS-DVU-102 GS-KSA BSI Transducers and sensors AUGPS-112. Automatic echo level meter is mounted on the wellhead pipe of the casing annulus. This device allows to measure liquid level depth and casing pressure in oil and gas wells. DDS-102. Automatic dynamometer is mounted between carrier bars of the pumping unit. It measures load and position on the polished rod and registers the dynamometer card and calculates the pump efficiency. The most important device to measure pump fillage and production rate and predicting malfunctions. GS-AMTU. Pressure gauge registers the pressure in the point of measurement. GS-DVU. Flow meter registers the flow in a pipe. General usage is for water injection system. GS-DT-102. Power sensor registers the current of power supply of the pumping unit. All transducers have the protection from environment IP67. All transducers have the wide temperature range of operation. All transducers are certified. Power and connection units UIK is the main controller for gathering data from transducers, for storing, preparing and sending information to the central host by -connection. GS-PU-102 is a smartphone to carry data from controller to central host or sending the registered data from controller by in a case of problem with GSM-connection. GS-KSA is a solar battery. It is used in a case of absence of power supply at the oil well. BSI is a notebook for gathering data from controller and for configuration. GS-CNTR is a power unit for controlling of the pumping unit. Workstations are equipped with the special software GEOSbor that provides the receive data from remote units, make storing in database, shows the data on the screen and prepare reports. Software is realized the viewing of incoming information, showing the log of events, alerts and emergencies. Software can create the control action for equipment (turn on/off, VFD) and also to configure the setup of controller. For small projects it is used the local database. For big projects there is used client-server database. Features of GEOSbor: Remote control for equipment Remote configuration of controller Analysis and preparation of registered data Optimization of equipment operation Set-points for detection the critical condition and failures Wide range of alarms to limit damage from possible failures Access to data with the flexible filter Export data to the customer database EFFICIENCY This automation system gives the evident results on the low and middle production rate oil wells which situated in remote and hard-toreach areas. After using this system the idle time of well is decreased, overhaul life is increased, the cost of manual measurements is decreased. The oil well is operated in optimal mode with the high efficiency. The payback period is no more than 6 months. The system ensures the reduction of the operating costs due to controlling the equipment. In average, after one year using of this system: -increase the production rate of well (after well was optimized under inflow rate) (5-7%); -reduction the costs for repair due to forecast of possible failures (6-8%); -overhaul period increasing (8-12%); -decreasing the cost of manual measurements (10-30%). Implementation of the new technologies of smart oil well is very efficient for enterprise. Gathering the data from remote units gives the understanding to the technologists the complete condition of oilfield operation.

AVAILABLE SUPPLY SETS FOR GEOSTAR-111.DD

ECHO is designed for automatic registration of liquid depth level and casing pressure in annulus of oil and gas wells, for transferring the registered data to the

System calculates the pump filling and makes decision about changing of pump speed. Remote flow meter GEOSTAR.DD.

PRESS Additional equipment Registration unit RU-21M3 is designed to connect to the transducers directly for checking and configuring.

4 AVAILABLE SUPPLY SETS FOR GEOSTAR-111.DD Remote automatic echo level meter GEOSTAR.DD.ECHO is designed for automatic registration of liquid depth level and casing pressure in annulus of oil and gas wells, for transferring the registered data to the central server by -connection. GEOSTAR.DD.ECHO GEOSTAR.DD.DYNA Remote automatic dynamometer GEOSTAR.DD.DYNA is designed for registration of dynamometer card of pumping unit. System calculates the pump filling and makes decision about changing of pump speed. Remote flow meter GEOSTAR.DD.FLOW is designed to measure and logging the production of liquid and transfer this data to central server by. It is used for injection water system. GEOSTAR.DD.FLOW Remote pressure gauge GEOSTAR.DD.PRESS is designed to measure the pressure and temperature and transferring it to the central server by. GEOSTAR.DD.PRESS Additional equipment Registration unit RU-21M3 is designed to connect to the transducers directly for checking and configuring. BSI (notebook) is the notebook with installed software GEOSbor. This device is used to configure the controller at the oil well, to get the registered data from controller, to calibrate the transducers. BSI (notebook) RU-21M3 GS-KSA Solar battery GS-KSA is designed for autonomous power supply. It consists the solar panels, battery controller and special lithium battery. Solar battery is chosen accordingly accordingly to the customer conditions. GS-PU-102 GS-PU-102 is portable device on the base of Android smartphone. It is designed to transfer data from controller to the central server in a case of absence of -connection at the oil well.

AUTOMATION TRANSDUCERS Pressure gauge Wellhead pressure gauge GS-AMTU is designed for diagnostic well logging.

Pressure gauge Manual data sheet ModBus RTU sheet GS-AMTU.485 Pressure measured range, MPa 0...25,40,60,100 Pressure accuracy, % F.S. 0.2 Pressure resolution, MPa 0.

. 18 hr Connection interface RS485 Connection thread M20*1,5 (on order) Voltage, V 12-24 Consumption current, ma 10 60x40x125 Weight, gm 400 Vulnerability

485 is designed to register single phase flow rate according to user-defined timetable scheme, to store it to the memory and send to the controller.

5 AUTOMATION TRANSDUCERS Pressure gauge Wellhead pressure gauge GS-AMTU is designed for diagnostic well logging. The gauge performs measurement of pressure, temperature and saves measurement results to the nonvolatile memory. Pressure gauge Manual data sheet ModBus RTU sheet GS-AMTU.485 Pressure measured range, MPa ,40,60,100 Pressure accuracy, % F.S. 0.2 Pressure resolution, MPa Flash-memory capacity, records Sample rate 1 sec.. 18 hr Connection interface RS485 Connection thread M20*1,5 (on order) Voltage, V Consumption current, ma 10 60x40x125 Weight, gm 400 Vulnerability category IP68 Flowmeter Fluid flow sensor GS-DVU is designed to register single phase flow rate according to user-defined timetable scheme, to store it to the memory and send to the controller. Flowmeter transducer Manual data sheet ModBus RTU sheet GS-DVU Pipeline fluid pressure range, MPa 0, Flow rate range, m /hour , , Flow rate error, % 0,5-1,0 Pipeline internal diameter, mm 50, 100 Voltage power supply, V Supply current, ma 20 Interface connection RS485 Interface protocol ModBus RTU Vulnerability category IP65 Weight, no more, kg x 160 x 140 Operating temperature, C -40º.. +60º

AUTOMATION TRANSDUCERS Dynamometer Dynamometer DDS-102 is used for remote registration of dynamometer card (load and position).

Dynamometer transducer Communication protocol Jacks for mounting DDS-102 Load measurement range, kg 0-10000, 0-20000 Load measurement full-scale

.10 Position measurement full-scale error, % ±5 Power supply voltage, V 12-24 Power consumption, ma 20 Interface RS-485 Communication protocol

485 is designed to register the liquid level depth and casing pressure in an oil and gas well.

6 AUTOMATION TRANSDUCERS Dynamometer Dynamometer DDS-102 is used for remote registration of dynamometer card (load and position). Dynamometer card analysis is the best way to monitor the operation of the pumping unit. Dynamometer transducer Communication protocol Jacks for mounting DDS-102 Load measurement range, kg , Load measurement full-scale error, % ±1 Position measurement range, m Position measurement full-scale error, % ±5 Power supply voltage, V Power consumption, ma 20 Interface RS-485 Communication protocol ModBus RTU 70х70х140 Weight, no more, kg 1,75 Operating temperature, C -40º +50º Automatic echo level meter Automatic echo level meter AUGPS is designed to register the liquid level depth and casing pressure in an oil and gas well. Can be used in any remote automation system to get the producing liquid level. Automatic echo level meter Manual datasheet MODBus protocol AUGPS Registered liquid level range,m Level measurement absolute error, m 0,6 Measured pressure range, MPa 0,1-6,0 Sample rate 1 min..45 days Power supply, V Interface RS485/Modbus RTU Operating temperature, ºC -40º...+50º Weight, kg 3

7 Automation devices Датчик Units of динамографа system Controller UIK provides the power supply and data channel for the connected transducers. Controller is used for gathering data from transducers, storing, preparing and sending information to the central host by -connection. Controller Remote connection type GSM / WiMAX / FM Internet connection Supported transducers analogue, ModBus RTU, Hart Power supply voltage, V Power consumption, W 10 Sample rate for data gathering 1 min - 30 days Maximal connected transducers, pcs 64 Memory capacity, pcs х200х120 Weight, kg 3,4 GS-PU-102- portable device on the base of Android smartphone. It is designed to transfer data from controller to the central server in a case of absence of connection at the oil well. GS-PU-102 Remote connection type GSM Internet connection Memory capacity, pcs Display color, 1024* х50х14 Weight, gr 150 GS-KSA solar battery. It is used in a case of absence of power supply at oil well. The c a p a c i t y o f b a t t e r y i s c a l c u l a t e d o n c o n d i t i o n s o f c u s t o m e r. GS-KSA Peak power, W 40 ± 5% Nominal voltage, V 12 Maximal voltage, V 17 Current in a point of maximal power, A 2,35 Short-circuit current, A 2,8 Open-circuit voltage, V х620х28 Weight, kg 5

Easy interface A large monitor, comprehensible interface allow getting any information required, or setting up the control system.

Easy interface A large monitor, comprehensible interface allow getting any information required, or setting up the control system. of new generation are intended for hand-operated, automatic and remote monitoring, control and protection of the ESP systems, equipped with asynchronous or ac motors, rated capacity up to 320 kw. ALSU