T78 - ConnectedProduction Solutions

Onshore Oil & Gas Production Solutions

PUBLIC

PUBLIC - 5058-CO900H Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.
 Agenda

What are ConnectedProductionSolutions?

Production Automation

Fundamental Solutions

Enabling Technologies

Advanced Analytics and Reasoning

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 Connected Enterprise
The ConnectedProduction Solution

Optimized for rapid value creation enabled by integrated control and information

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 ConnectedProduction Solutions
ConnectedProduction solutions provide Oil & Gas producers the secure
connectivity and scalability that is required to visualized and optimize production
from the well head to the point of custody transfer.
Deployed within an operations environment (on premise), or in the cloud, Intelligent Asset
ConnectedProduction solutions provide a complete set of capabilities, including:
Visualization
Historical data
Data modeling
Reasoning and analytics
Mobility
Open architecture that enables third-party connectivity
Intelligent assets provide contextualized data within a ConnectedProduction
system, and can be any combination of third-party assets and intelligent assets
offered by Rockwell Automation
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 ConnectedProduction Solutions
Functional Overview
Deployed on-premise or in the cloud
Collaboration /Role Based Content Asset Management
Data Model Visualization Reasoning
Intelligent Asset
Workflows Historical Data Mobile / web
Data Connectors / Gateways Application Interfaces

OptiLift Infrastructure Data

Repository
OptiSIS DCS / SIS
Data
Repository
Turbo Machinery RTU
Control
Data
Field Devices
OEM Repository

Intelligent Device Data

Assets Assets Assets Devices (and third-party systems)

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 ConnectedProduction Solutions
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
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 ConnectedProduction Solutions
On-Premise Large Architecture
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)

Scalable Architecture
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 ConnectedProduction Solutions
Cloud Architecture

Rockwell Automation Cloud

(Microsoft Azure)

Logix
Gateway
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

Scalable Architecture
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 ConnectedProduction Solutions?
Security
Off Premise On Premise
Integrated Key ISA99
Management ISA/IEC 62443

Isolated
Isolated Industrial Data Center (IDC) E2000
Customer Data
Customer Data
Hosting & Storage
Storage
FTVantagePoint EMI Server & Client
FTView Server & Client
FTHistorian SE

Analytics Isolated
Role Based
Customer Data
FTViewPoint Client
OPC Server (KEPWare &/or RSLinx) Controlled
Authentication Field Access
Storage

Collaborative
Security
LAN, WAN MPLS
Wireless, Cell VPN Secure IPSec / Secure
Integrated
Geo Locked Unidirectional GREVPN Bidirectional
Services
Satellite Authenticated
Gateway
Communications Router
Communication
over Select Ports
Over Port 443

Cloud
Gateway

Field
Assets

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 ConnectedProduction Solutions
Visualization, Mobile and web
FactoryTalk View SE
Scalable HMI Solutions
Configure your application from anywhere
Scale from single station to multi-client / multi-server systems on the network and easily make changes
Create custom process to a running system with remote, multi-user
graphics, as required configuration capability
Customize pre-defined
graphics, as required Scalable Architecture from single station
Create alarms unique HMI to multi-client/multi-server system
to implementation
Create reports, per Maximize system availability with built-in
project requirements
Primary Secondary failure detection and recovery
Server Server
Robust client side scripting to extend
applications for your specific needs
Built-in library of over 5000 pre-designed
graphical symbols
Built-in security model, linked to existing
IT infrastructure

10
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 ConnectedProduction Solutions
Workflows
Configurable workflows
Define implementation-
specific workflows Standard environment,
Implement, and supports custom workflows
integrate workflows into
Connect Production Facilitates workflow execution
Integrate (persistence, multiple
implementation-specific instances, etc.)
producers/ consumers
of workflow data
Built on off-the-shelf
technology
Designed for any stakeholder
Capable of acting on data from any
data source within the system
Model driven, configurable workflows
support various use cases, for example:
Initiated by ERP (SAP)
Initiated by User (SOP)
Initiated by Event
(i.e., process condition)
Predefined ConnectedProduction
Activities (building blocks to define
customized workflows)
Stakeholders
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 ConnectedProduction Solutions
Reasoning
Define interfaces
Integrate third-party
models Open architecture allows for integration
Define and implement of third-party analytics, reasoning,
visualization, reports, production modeling, etc.
workflows, etc.
Can be integrated, via plug-in, directly
into the well type model, providing data
context
Preferred connectivity can be achieved
by implementing a native data connector
API Can have multiple analytics engines
within a system
Resulting data set can be utilized in:
Model
Visualization
Plug-in
Workflows
Data
Any system with
access to model

Third-Party Interface (may have multiple)

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 ConnectedProduction Solutions
Asset Management
FactoryTalk AssetCentre
Version Control / Source Control
Centrally store files programs, configurations, SOPs, CAD
documents, and more
Automatic version control helps ensure proper file management
Maintains single master relationships
Allows for additional users to get a copy while maintaining the
master ownership
Audit Trail
Audit / Event messages include logged time, time of occurrence
(when), user name (who), device, computer name (where) and
action taken (what)
Scheduled automatic backup of plant-floor asset configuration
Disaster Recovery
Define implementation-
specific assets Optionally compares the backup configuration against an archived
Implement desired version
asset management Latest or specific version
features (for example,
disaster recovery) Pinned version
Create version when difference detected
Difference report in Event database, and email

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 Agenda

What are ConnectedProduction Solutions?

Production Automation

Fundamental Solutions

Enabling Technologies

Advanced Analytics and Reasoning

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 Production Automation
Well Manager Solution
Scalable Multi-Well Control:
ControlLogix based - for large sites with up to
32 artificial lift wells
CompactLogix based - for small sites with up to
eight artificial lift wells
Incorporates Allen-Bradley Flex I/O, PowerFlex VFD,
and OptiLift artificial lift technologies
Configure and Run Artificial Lift and Optimization: (Black Oil Model, Well Test, Tank Management, etc.).
Sucker Rod Pump (SRP)
Plunger Lift
Gas Lift
Electric Submersible Pump (ESP)
Progressive Cavity Pump (PCP)
Natural Flow
Black Oil Model, Well Test, Tank Management, and so forth.
Configure and Run Electronic Flow Metering:
Custody Transfer metering for Gas and Liquids
Up to 80 flow runs

EtherNet/IP Production Automation Network:

Connects to Modbus field devices and third-party controllers
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 Production Automation
Well Manager Solution

Oil & Gas applications in Logix configure and run

Rod Pump Controller
Plunger Lift
Gas Lift
Electric Submersible Pump
Progressive Cavity Pump
Natural Flow

Configure and run HMI applications

for artificial lift operations and
electronic flow measurement.
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 Production Automation
Intelligent Assets

Oil & Gas Extraction Enhanced Recovery Power Control Fiscal Measurement Treatment & Storage
Wellhead automation Injection pump controls LV / MV drives LACT unit control Gas treatment and
Natural lift systems Injection manifolds controls Electrical control house Metering and measurement compression
Artificial lift systems Chemical storage systems TMC / Compressor control
Injection systems Treating liquids blending Oil treatment and storage
Safety systems process control Produced water treatment
Separation systems Steam generation and storage
Gas compression (Black Oil Model, Well Test, Tank Management, and so forth).

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 Production Automation
SCADA, DOF, Intelligent asset auto discovery

1. ConnectedProduction services, automatically, detects a

newModel,
(Black Oil assetWell Test, Tank Management, and so forth).
2. User is prompted with Asset Discovery wizard
3. User is guided, step by step, to configure:
Name
Description
OptiLift roadmap of intelligent assets for artificial lift Location details
OptiLift-WM (Well Monitoring) 4. Asset is available for use
OptiLift -NF (Natural Lift)
OptiLift-ESP (Electrical Submersible Pump)
OptiLift-PCP (Progressive Cavity Pump)
OptiLift-RPC (Rod Pump Controller)
OptiLift-GL (Gas Lift)
OptiLift-PL (Plunger Lift)

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 Production Automation
Production Safety, OptiSIS, Intelligent Assets
Engineered to comply with IEC61508/IEC61511
safety manuals.
SIL3, Fail-Safe or Fault Tolerant hardware
configurations
50 and 100 I/O sizes available, Universal inputs
Simple, intuitive, configurable, cause and effect
configuration interface
Configure safety functions no programming
required.
Pressure IR3 Gas Available in either safe area (NEMA 4/IP54) or
Transmitter Detector
hazardous area (NEMA 4X/IP66) enclosure
Excellent choice to migrate legacy safety solutions
Flame not compliant with IEC61508/IEC61511
Detector Cost effective process safety solution
Solenoid
Valve
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 Agenda

What are ConnectedProduction Solutions?

Production Automation

Fundamental Solutions

Enabling Technologies

Advanced Analytics and Reasoning

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

 Fundamental Solutions
Artificial Lift Operations

Sucker Rod Pump Plunger Lift Natural Flow

Gas Lift Progressive Cavity Pump (PCP) Electric Submersible Pump (ESP)

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 Fundamental Solutions
Artificial Lift Operations
Artificial Lift Optimization Intelligent Assets:
Rod Pump Control (complete) ConnectedProduction
Plunger Lift (in progress) Well Manager
Gas Lift (licensable components)
Natural Flow
Electric Submersible Pump
Progressive Cavity Pump
OptiLift Packaged Solutions
(Standalone)

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 Fundamental Solutions
OptiLift WM (Well Monitor)
Features:
High-performance iRecv RTU Gateway
to SCADA System
Long range iSens wireless pressure
and temperature transmitters
Provides real-time data monitoring
and reliable local well shutdown control
Configurable Alarm Logic for alarming and local control
Custom Enclosure option
Solar Power option

RS-232/485
Modbus RTU Slave

Wired I/O Devices

(shutin valve,
choke, sensors)

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 Fundamental Solutions
OptiLift PL (Plunger Lift)
Optimizes lifetime of well by mitigating the effects of liquid
loading
Designed for deployment on gas and gas/oil wells
Can be installed to existing mechanical plunger systems
(500,000 gas wells in the U.S.)
Supports six operating modes
Self learning, adapts / tunes to well conditions
Protects well during abnormal situations
Records production data sets at multiple intervals (daily,
monthly, lifetime)
Licensable component of Well Manager
Designed for interface with ConnectedProduction services
Stand alone OptiLift-PL, available soon

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 Fundamental Solutions
OptiLift RPC (Rod Pump Controller)
Supports six modes of operation:
Fixed Speed (standalone) Variable Speed (Allen-Bradley Drive, or third-party drive)
Pump off (POC) Pump off (POC)
Time based Pump Fillage
Manual Manual
Dynamometer card that is based pump-off control (requires
load cell and inclinometer)
Continuous true load and position monitoring
Calculated down hole card
Real time well problem detection and load violations
Well production performance statistics
Various pre-designed power options
Drive sizes ranging from 25 hp to 125 hp
Traditional dynamic braking
Energy-efficient Active Front End (IEEE519)

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 Fundamental Solutions
Electronic Flow Metering
ProSoft AFC Flow Computer
Measurement of hydrocarbon gases and liquids using currently
accepted industry measurement standards
Archiving for each meter run, hourly for two days (up to 35 days
optional) and daily for one month (35 records) under default
configuration.
Process Variables may be in-chassis analog I/O, distributed I/O,
iSens transmitters, or third-party transmitters

rDAC iXMS for solar-powered

and remote site flow metering

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 Agenda

What are ConnectedProduction Solutions?

Production Automation

Fundamental Solutions

Enabling Technologies

Advanced Analytics and Reasoning

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

 Enabling Technologies
Allen-Bradley PLCs and PACs
Scalable Controller Portfolio
Up to 32 artificial lift wells
Up to 80 flow runs
Robust Network Infrastructure
CISCO technology and EtherNet/IP
with redundancy options at every level

Comprehensive Integration
The broadest range of traditional I/O and intelligent devices

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 Enabling Technologies
Intelligent RTUs
High performance RTU with PLC-like features Low-power consumption RTU
IEC 61131 programming with ISaGRAF Workbench AGA 3, 7, and 8 API 21.1 compliant gas flow metering
Embedded web server Plug-and-play radio module for telemetry applications
Gateway for up to 100 rDAC transmitters Programmable Sleep Interval, and Transmit Interval
Embedded web server

8-28Vdc, 4 W 730 Vdc, 350 mW continuous, 0.45 mW in sleep mode

-40C to 85C operating temperature
-40C to 85C operating temperature
32 MHz CPU
800 MHz CPU
10/100 Ethernet Port, (2) RS-485 ports, RS-232 port, USB port, I2C port
(2) 10/100 Ethernet Ports, (2) RS-485 ports, (2) RS-232 ports, USB host port
8 AI 24 bit (0-5 Vdc or 0-20 mA), two AO 12 bit (15 Vdc or 420 mA)
(8) DI sinking, (8) DO sinking, rated 500 mA, (1) DI hardware interrupt 8 DI sinking (one DI is HSC), 8 DO solid-state relay rated 350 mA
(8) AI 24bit (05 Vdc, 420mA), (2) AO 12 bit (05Vdc or 420 mA) 1 RTD input, 12 bit, 100 ohm platinum
Optional Pluggable Wireless Card (900 MHz and 2.4 GHz) Optional Pluggable Wireless Card (900 MHz and 2.4 GHz)
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 Enabling Technologies
Wireless Transmitters
Long-range embedded wireless communications
No external power required
Configurable Sleep Interval, and Transmit Interval
Data is pushed to data concentrator

iSensMV iSensGP iSensDP iSensT2

Multivariable transmitter that Gauge pressure transmitter. Transmitter that measures absolute Temperature transmitter with
measures absolute and differential Five ranges available, up to 10,000 pressure and differential pressure. -17C to 200C range (0392F)
pressure, and temperature. psi. Five ranges available, up to 3,000 900 MHz or 2.4 GHz radio
Seven ranges available with DP to 900 MHz or 2.4 GHz radio H0 available.
840" H2O, AP to 1,500 psia. 900 MHz or 2.4 GHz radio
900 MHz or 2.4 GHz radio
Wired version available.

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 Enabling Technologies
Wireless Data Acquisition RTUs and Gateways
Data Acquisition RTUs Wireless Transmitter to Modbus Gateway EtherNet/IP to
Battery Powered (no solar required) Wireless Repeater Modbus TCP
Embedded Wireless Communications RTU function via Embedded I/O Gateway

iXS8 iSensIO iRecv iExtnd Achilles certified EtherNet/IP to

Configurable sleep Interval Configurable sleep Interval Wireless gateway/RTU for Wireless repeater for RTUs, Modbus TCP converter.
Configurable transmit interval Configurable transmit interval transmitters and DA RTUs transmitters, and iRecv. Supports RTUs and third-party
(3) AI, 12 bit (0-5Vdc,420mA) 734.0 Vdc Used to extend transmission Modbus TCP devices.
(6) AI, 12 bit (05Vdc,420 mA)
(1) AO (15Vdc, 420mA) (2) DI, (2) DO range or to navigate around (2) independent TCP ports
(1) AO, 12 bit(0-5Vdc,4-20mA)
(2) DI, (324 Vac or Vdc) (4) AI (05Vdc,420mA) transmission obstacles. Buffers events / trends
(2) DI, (324 Vac or Vdc)
(1) DI event driven interrupt (2) AO (15Vdc,420mA) Supports two radios EtherNet/IP Class 1: Add RTU
(1) DI event driven interrupt
(2) DO (1) AI for battery level (900 MHz or 2.4 GHz). into Logix I/O tree (AOP)
(1) AI for battery level
(1) AI for battery level (1) AI for temperature EtherNet/IP Class 3: Polling
(1) AI for temperature
AI for temperature (1) RS232/RS485 serial port from Logix (MSG), exception
(1) A/D channel for RTD
900 MHz or 2.4 GHz radio 900 MHz or 2.4 GHz radio reporting from remote site.
900 MHz or 2.4 GHz radio
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 Agenda

What are ConnectedProduction Solutions?

Production Automation

Fundamental Solutions

Enabling Technologies

Advanced Analytics and Reasoning

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

 Advanced Analytics and Reasoning
SCADA, DOF, and RPC analytics
Monitor

The OptiLift RPC measures surface

conditions and calculates down hole
conditions, producing surface and downhole
cards
Analyze ConnectedProduction RPC analytics,
analyzes the condition of the well and pump,
which is based on downhole card
ConnectedProduction RPC analytics, monitors
the shape of the down hole card and identifies:
The work that is done by the pump
Optimize The pump fillage
Fluid pound conditions
Predict probability of failures, by failure mode

Predict
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 Advanced Analytics and Reasoning
Flow Measurement, Virtual Flow Metering

Configuration Black Oil Computes three-phase flow (oil, gas and water) based on well
Model configuration, and measured pressures and temperatures
Base Assay Coefficients Produces / generates:
Water Cut Well profile P, T, flow regimes
Initial Well Test Data
Base PVT Data
Well Well frictional and elevation pressure drops / pressure profile
Well temperature profile
Well characteristics
Well performance curves / parametric
Reservoir Data
Well operating envelope (next phase)
Measured Values GOSP Provides well performance analysis:
Forecasting aid, what-if analysis, and performance improvement
Parameter impacts: for example, water-cut, reservoir pressure,
and PI
Casing Pressure Production
Enables well test cross-check / validation
Casing Temperature
Infers values between well tests, improving production accuracy and
Tubing Pressure providing early problem detection
Tubing Temperature Reservoir Enables test by exception, streamlining well test scheduling
To Terminus Does not require a three-phase meter
Works on a broader range of conditions vs. three-phase meter
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Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.