onshore extraction application guide

Building a New Electric World

Oil & Gas Onshore ExtractionApplication Guide

Maximizeenergy effi ciency.

Improveprocess integrity.

Increasepersonnel andmachine safety.

Table of contents

UPSTREAM ONSHORE EXTRACTION ................................5

Drilling and completion ..................................................................... 5

Upstream onshore extraction ............................................................ 5

Conventional/pumpjack extraction .................................................... 6

Power distribution, control and automation equipment requirements .................................................................... 6

Power distribution ................................................................................6

Motor control/SCADA/RTU ...................................................................7

Problems encountered during pumpjack operation .................................8

Schneider Electric value proposition ................................................. 9

Electrical system management .............................................................9

Altivar® 71 Well Manager System ........................................................11

Altivar 71 pump fi ll controller ..............................................................12

Prefabricated electrical buildings (PEBs) .............................................16

UNCONVENTIONAL EXTRACTION ................................... 16

Oil sands and oil shale .................................................................... 17

Mining ..............................................................................................17

In situ recovery .................................................................................17Steam assisted gravity drainage (SAGD) ....................................17

Upgrading bitumen ............................................................................18

Power distribution, control and automation equipment requirements ....................................................................18

Oil sands and oil shale ..............................................................18

Gas ..........................................................................................19

Schneider Electric value proposition ............................................... 20

Oil sands and oil shale ......................................................................20

Gas .................................................................................................28

GLOBAL CUSTOMER REFERENCES ................................. 29

GLOSSARY OF TERMS ................................................ 35

5

Upstream onshore extraction

Drilling and completion Before extraction of oil and gas from underground reservoirs can begin, wells must be drilled down into these reservoirs. (As it is part of the exploration process, drilling will not be covered in depth in this chapter).

Oil and gas wells are drilled by spinning a bit at the bottom of a drillstem made of steel pipe. This work is done from drilling rigs. Wells vary in depth from 600 metres (1000 feet) to several kilometres (0.6 km = 1 mile).

To gain better access to underground oil or gas formations, and drill multiple wells from a single surface location, the direction of drilling can be altered underground. Specialized bits, remote controls and downhole motors turned by mud circulation are used in directional drilling.

Once a surface hole is drilled to a depth of 60 to 400 metres, the drillstem is removed and a steel pipe is cemented into the borehole to keep the wall from collapsing. The casing is punctured to allow oil or gas to fl ow into the well.

At the surface wellhead, controls and valves are installed to control the production/extraction fl ow.

Upstream onshore extractionTwo methods are used to extract oil and gas:

■ Conventional extraction of oil and gas – via pumpjacks

■ Unconventional extraction of bitumen from oil sands – mining or in-siteextraction (drilling)

World activity for conventional and unconventional drilling is shown inthe chart below.

World oil and gas drilling activity(Number of wells drilled)Source: World Oil Magazine.

North,Centraland South America74,511

A

Africa1,100

E

Asia and Oceana15,618

F

Western Europe650

B

EasternEuropeand former USSR5,865

C

MiddleEast1,867

D

6

Conventional/pumpjack extraction If formation pressure is not suffi cient to force the liquids or gas to the surface, a pump is lowered into the well tubing. Also referred to as “artifi cial lift,” this pump is powered either by rotation or by the up-and-down movement of a pumpjack.

There are several methods to maintain or improve the well’s ability to extractoil or gas:

■ Injecting acids to dissolve channels in the rock around the well (acidizing); and

■ Injecting high-pressure water or oil to create cracks in the rock formation(fracturing or fracing). Water or gas, such as nitrogen, can be injected tomaintain reservoir pressure as the oil or gas is removed

Power distribution, control and automation equipment requirements

Power distribution

Electrical power is distributed to oil and gas fi elds by a combination of

■ A low voltage (less than 5 kV) substation

■ A medium voltage (5 kV to 15 kV) substation

◆ A 13.8 kV substation could require up to 20 MVA

■ A dual redundant power source of up to 13.8 kV, supplied by a thermoelectrical central unit using two gas turbogenerators (approximately 12 MW)

■ The utility substation

The electrical system is usually fi tted with reclosers and automated manoeuvre and protection devices and is controlled from a central SCADA location. PLCs relay data to the SCADA location from the turbines, generators and feeders. This operation center also protects, monitors and conducts automatic switching and system alarming. Electrical power needed for gathering station induction engines, injection steam generators, and wells with units of mechanical and centrifuge pumping is supplied by 15 kVA to 150 kVA substations and 13.8/0.48 kV transformers. Building facilities, external lighting, communication and automation are powered by 575/480/380-220 V, 5 kVA to 15 kVA transformers. 13.8 kV, 150 kVA to 1200 kVA capacitor banks are connected to the electrical distribution feeders to regulate voltage and correct power factor.

Electrical system failures are frequently caused by transient or permanent defects in the distribution network. Additional problems include:

■ Phase grounding short-circuit resulting from conductor breakdown

■ Phase grounding short-circuit caused by damage to the pin and disk isolators

■ Lack of phase caused by hot spot in the connections

■ Diffi culty identifying defect type and site

■ Long manoeuvre times

■ Blockage of automatic switching

■ Lack of remote monitoring

7

Motor control/SCADA/RTU

Typical automation applications include

■ Steam injection

■ Pump and compressor control

■ Water re-injection

■ Blocking valve control

■ SCADA alarming and reporting

■ Flow metering

Electrical system diagram

8

Typical production fi eld SCADA layout

Problems encountered during pumpjack operation

Well conditions change over time. Deteriorating well conditions lead to incomplete fi lling and cause fl uid pound, energy waste and gas lock. To improve these conditions and ensure 100% pump fi ll per stroke, pumps must be installed and geared up to match the existing well conditions.

■ Pump off occurs when the pump tries to pump fl uid faster than what the well can produce. The sub surface pump chamber only partially fi lls. The pump becomes ineffi cient and severe mechanical deterioration occurs.

■ Fluid pound occurs when, after partial fi lling of the pump with gas (due to pump off), the plunger, on its downward travel hits the fl uid in the partially full chamber, sending a shock wave up the rod string. This often causes rod breakage, which increases downtime, production loss and maintenance costs while jeopardizing on-site repair technician safety.

■ Gas lock occurs when the pump has the ability to pump more fl uid than is available in the reservoir. When the pump fi ll is very low, the plunger moves up and down with no fl uid in the chamber, wasting energy and causing extra wear on the now un-lubricated plunger. This considerably decreases the mean time before failure of mechanical components and increases maintenance costs.

■ Energy waste of up to 30% occurs when the total energy consumed in one stroke is not proportional to the pump fi ll level. This signifi cantly increases operating costs of large pump fi eld operators.

9

Schneider Electric value propositionSchneider Electric offers a complete electrical, control and automation solution for pumpjack applications – from single well sites to multi-pump clusters and pads. Our cost-effective and maintenance-friendly equipment maximizes uptime while providing performance, functionality, fl exibility and savings.

Integration of control, automation and power products is seamless to optimize operations. Using off-the-shelf components, a system can easily be confi gured for unique applications and network sizes (number of wells). A wide variety of communication protocols is available (Modbus®, Devicenet, Profi bus, etc.), so that all the necessary components – solid state motor protection, variable speed AC drives, PLCs, HMIs and metering devices – can seamlessly communicate to either a local interface or a remote SCADA host. The result: more timely and accurate information and reduced downtime.

Schneider Electric offers a complete IEC/AINSI-NEMA solution that can be sourced worldwide by OEMs, system integrators and end-users. Our worldwide network of fi eld application engineers provides expert support for all your integration challenges.

Electrical system management

To manage electrical systems, Schneider Electric can install a central SCADA system that includes HMIs to protect, manoeuvre, monitor and store data, and conduct automatic switching and alarming.

When the open DNP3 protocol is used as the main system protocol, the user ■ Facilitates integration of devices from different vendors

■ Standardizes existing automation hardware and software

When reclosers and sectionalizer switches are installed with RTUs at various points in the feeders, the user facilitates protection, manoeuvreing and data monitoring. The RTUs communicate to a central terminal unit via radio-modem and the DNP3 protocol.

10

Circuit breaker protection relays and medium-voltage reclosers are multifunctional and can monitor voltage, current, power and energy via digital programmable I/O and an RS-485 port that communicates to the network over Modbus® and DNP3. Integrated monitoring and control of all electrical system components enables management of charge fl ow, regulation and stability of voltage and electrical system alarm events, and their quick recovery in case of failure.

This Schneider Electric solution provides:

■ Improved time to recover from system failures and routine manoeuvres(due to the installation of automatic reclosers and sectionalizer switches)

■ Improved electrical system diagnostics (and fault analysis) and operator safety through remote acquisition of digital and analog data from protection devices

■ Increased uptime

■ More effective coordination and selectivity between protection devices(due to the installation of new reclosers)

■ Improved repair time and corrective maintenance (due to improveddiagnostics and reduced area affected by the failure, and reduced timeneeded for visual inspection)

■ Improved electrical system management and optimization

The Telemecanique® Altivar® 71 AC variable speed drive provides users with two solutions tailored to the needs of pumpjack operations – the Well Manager System and the Pump Fill Control System.

SCADA for electrical system management

Engineering PC

Redundant PLC Master Hub

Drop

Momentum I/O

Magelis HMI

PC - basedSCADA

PC - basedSCADA

Hub

Momentum I/O

Redundant PLC Master

Drop

SEPAM40 relay

PowerLogic PM850 power meter

Site 1

Site 2

Operation PC

Engineering PC

11

Altivar® 71 Well Manager System

Advanced pump control solutions minimize the energy cost per barrel of crude extracted. Telemecanique® Altivar 71 AC variable speed drives provide near-unity power factor at all speeds and loads to avoid utility power factor penalties. The drives’ Energy Adaptation (ENA) system for unbalanced loads facilitates macro-confi guration, eliminating the need for braking units.

Additional benefi ts from using the Altivar 71 Well Manager System:

■ A gearbox ratio monitor automatically computes the overall ratio between the motor and crank shaft with each stroke of the pump, and a gearbox torque limiter protects the gearbox from excessive torque loads.

■ A pump speed monitor provides instantaneous and average pump speeds.

■ Sensors detect weight variations and arm position. Software analyzes the data and calculates the fl uid level and percentage offl oad. The variable speed drive adjusts the maximum and minimum pump speed.

■ An enhanced RTU protocol allows effi cient transfer of data locally and remotely. The RTU panel monitors phase/fault sequence and asymmetry, under and overvoltage. A PLC facilitates diagnostics. The panel automatically shuts down if the interior temperature exceeds a preset limit, and a no-break UPS allows continued operation during power outages. The panel is IP65-rated and is fi eld tested to withstand 150 kM/h winds and temperatures from -20°C to + 45°C. Thermal insulation maximizes ruggedness.

Typical control and automation panel for a single pumpjack

Altivar 71 variable speed drive

12

Altivar® 71 pump fi ll controller

The new Altivar 71 variable speed drive “pump fi ll controller” (PFC) function provides a cost effective, easy-to-retrofi t solution for problems associated with rod pump speed control. It adjusts the pump speed to aim for 100% pump fi ll. This avoids gas lock and fl uid pound, and gets the best possible energy effi ciency – up to 30% in energy savings.

It detects a pump-off condition by accurately analyzing the torque demand from the rod pump and reducing the speed as required before the condition can cause serious damage. Alternatively, as the fl uid produced by the well increases, the PFC will increase the speed of the pump. In this way, the rod pump’s performance is optimized by matching the pump speed to the fl uid infl ow of the well, thereby improving the pump effi ciency and reducing maintenance costs.

The Altivar 71 PFC function considerably simplifi es previous load cell-based pump-off controller technologies (which employ a load cell mounted on the hanger rod to measure the weight of the oil that is lifted during each stroke and a position potentiometer mounted on the beam to determine the rod position).

Typical systems architecture for a multi-site pumpjack operation

WI-FICOMMUNICATIONS

Customer Intranet

Ethernet (Panel)

Substation Pumpjack1 Pumpjack2 Pumpjack3

RTU 1M340 PLC

RTU 3M340 PLC

RTU 2M340 PLC

NuLecreclosers

RTU 4M340 PLC

ModbusHub

ETG 1000Modbus/Ethernet

Bridge

ConneXiumSwitch

RTU 5M340 PLC

ZAP500analyzer

High pressurepumping unit

ATV71 variablespeed drive

13

Electrical EnclosureElectrical Enclosure

Motor

Gearbox

Counter Balance Weights

Position Sensor

BeamHorse Head

UpStroke

DownStroke

Polished Rod

Stuffing Box

Alternative PositionSensor Location

Crank

Rod String

Sucker RodPump Assembly

Travelling Valve

Plunger

Standing Valve

Reservoir

Dirty Ground

Rod pump layout

14

The Altivar® 71 AC variable speed drive is contained in a single unit – no external controller or load cell is required.

Balancing screens are provided to determine the correct adjustment of the counter balance weights by comparing the peak torque during the up stroke with the peak down stroke. This information can then be used to adjust the counterbalance weights, simplifying the rod pump setup procedure. The drive consists of a standard Altivar 71 with a Controller Inside card and a preloaded Co-De-Sys program. A simple external proximity switch is required to detect the position of the crank as it rotates. The drive’s “ Optimiser” software – developed using LabView software – is provided on CD free of charge to set up the drive.

Ranging from 0.75 kW to 400 kW, 380 VAC to 480 VAC, the Altivar 71 can speed pumps up to increase motor effi ciency by 5 to 20%.

The Altivar 71 ENA function controls the regenerated energy via dynamic brake resistors. It adjusts the speed to absorb the regenerative energy as kineticenergy in the moving mechanism. No additional equipment is required and noenergy is wasted.

Easy to set up, the Altivar 71 PFC is robust against changing mechanical conditions. It boasts a wide temperature – from -10°C to +50°C. It has a fullycoated option to IEC 60721-3-2 class 3C2. It also has an IP54 option and is CE,UL and cUL approved.

An HMI and messaging provide full system operation feedback and status – current pump fi ll level/status, stroke direction, strokes per minute, crank position in degrees or percentage, pump torque and speed, motor power, RPM, output voltage and current, motor temperature, heatsink and internal temperature, and I/O status and value indication.

A balance display indicates the actual effectiveness of the position of thecounter weights.

Stroke length monitoring via a position limit switch monitors belt slippage, switch failure or incorrect gearing (the PFC is disabled and an alarm is generated).

An energy meter displays the estimated kWh consumed by the AC drive.

Motor Torque

Pump Energy Consumption

Motor Speed

Rod Position Calculator

High Level

Span

Zero

Low Level 1

-

+

0

Low Level 2

Limit SwitchPump Fill Calculator Span & Zero set up via RMO

Pump Fill Comparator

Speed Adjust Algorithm

Speed Reference

Adjust Rate/Stroke

Minimum Speed

Lo

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osi

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n Hig

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Block diagram of the pump fi ll controller

15

The PC-based Altivar® 71 Optimizer software fi ne tunes and monitors the system. Compatible with an external load cell connected to an analogue input, thissoftware features.

■ A Setup Tab to confi gure serial communications,

■ A Dynamometer Tab to calibrate the pump fi ll controller,

■ A Drive Monitor Tab to monitor various drive and pump parameters – torque, current, DC bus voltage, motor speed, rod position, position sensor and power,

16

■ A Read Saved Dyno Tab to allow the user to view previously saved graphs, and

■ A Balance Setup Tab to adjust the counter balance weights for optimumpump effi ciency.

Prefabricated electrical buildings (PEBs)

Schneider Electric partners with civil, mechanical and electrical companies to custom-fabricate PEBs. These “powerhouses” provide HVAC, lighting, security and motor control for pumpjack operations. They contain Schneider Electric switchgear and motor control centres.

Unconventional extraction Specifi c types of oil and gas are extracted by “unconventional” methods.

■ Oil sands and oil shaleBitumen is extracted from oil sands or oil shale by mining or in situ processes. Both processes require bitumen separation from sand or shale and upgrading into marketable commodities such as diesel, jet fuel or gasoline. A more detailed description of these processes is discussed on the following pages.

■ Coal bed methane (CBM)The methane in coal seams can occur as dry gas or be associated with saltor fresh water. Dry gas is extracted in the same way as conventional naturalgas. If associated with water, the CBM well is fi rst used to remove the waterfrom the coal.

■ Shale gasShale gas is natural gas that is produced from reservoirs predominantly composed of shale with lesser amounts of other fi ne-grained rocks, rather than from more conventional sandstone or limestone reservoirs. Similar drilling and production techniques are used in gas shale formations as in conventional natural gas, but due to a lack of permeability, gas shale formations almost always require fracture stimulation and often higher well densities.

17

Oil sands and oil shale

Mining

Bitumen deposits located near the surface are mined using a truck and shovel open-pit mining technique. Hydraulic electric-powered shovels load oil sands onto enormous trucks. These trucks deliver their loads into a crusher that breaks up the clumps and removes rocks from the sand. Water is mixed with the screened clumps to create slurry. This thick fl uid is then carried by pipeline (hydrotransport) to a processing plant (about six cubic metres of mined oil sand are required to produce one cubic metre of marketable synthetic crude oil).

In situ recovery

When bitumen deposits are too deep to be surface-mined, they are extracted from underground reservoirs using in situ techniques. Various techniques have been developed to draw bitumen to the surface. Steam injection is currently the most cost-effective and least environmentally invasive method of liquefying the bitumen in underground oil sands and oil shale to enable extraction. However, solvent injection and fi re fl ood (injecting oxygen and burning part of the resource) methods have also been used.

Steam assisted gravity drainage (SAGD)

SAGD is the preferred technology for in situ production. It involves drilling two parallel horizontal wells – a steam injection well and producing well – one above the other. The injection well is typically located fi ve metres above the producing well. The upper well injects steam and, as the bitumen drains downward, a lower horizontal well pumps it to the surface. The steam heats the bitumen and aids in the drainage of the oil to the production well via gravity and a pressure differential.

Oil sands mining process

18

Upgrading bitumen

Bitumen can be directly used as asphalt for road construction. Otherwise, itrequires upgrading into synthetic light crude, which then can be refi ned into other petroleum products.

Upgrading typically involves hydrogenation, a process that splits the hydrogenfrom methane (natural gas) and uses that hydrogen to transform the bitumen into synthetic light crude.

Power distribution, control and automation equipment requirements


Oil sands/shale extraction operations run 24/7 to maximize revenue. Their electrical, control and automation systems must therefore:

■ Provide a high level of availability and reliability, even in extreme temperature. PLCs are key to automation systems, because their robust design makes them well-suited for automating oil sands operations.

■ Distribute power around the mine site at medium voltage levels. Power distribution (up to 36 kV switchgear for surface mining and up to 5 kV for SAGD) and motor control equipment must provide maximum voltage, continuous current ratings and interrupting ratings.

Steam assisted gravity drainage process

19

■ Integrate major power and control equipment into prefabricated electrical buildings (PEBs) to facilitate equipment installation and commissioning.

■ Provide reliable and secure communications, which is in most cases redundant (wireless, twisted pair, fi bre optic, laser point-to-point, etc.).

■ Provide system/device redundancy (hot standby).

■ Have best-in-class safety features to help ensure the security of their communication systems. Controllers must be virus-free and prevent unauthorized changes to programs.

■ Provide a high level of application, technical and fi eld service support.

■ Minimize the number of PCs/computers to operate a SAGD site. Again, PLCs are key to automation systems, because their ability to execute custom mathematical calculations allows the user to reduce the number of PCs/computers required to operate a SAGD site.

■ Minimize steam and energy costs while maximizing SAGD well production. To accomplish this, operators require PLCs that can perform cycle time calculations for steam injection schedules. The equation for performing this calculation is considered to be intellectual property and proprietary by many oil companies, and is therefore not commonly shared.

Additional requirements are as follows:

■ To maximize uptime in surface mining operations, large bulk material handling systems (conveyors and pipelines) require a high level of variable speed drive coordination.

■ The use of multiple high horsepower variable speed drives generates high levels of total harmonic distortion. Harmonic mitigation equipment is required to eliminate unwanted harmonics, thus minimizing downtime and energy consumption (which, in turn, reduces energy consumption surcharges where applicable).

■ Heavy power usage requires power monitoring and metering systems to identify opportunities for optimizing energy usage and predicting/avoiding power outages.

■ The hazardous environment resulting from heavy power usage and volatile, fl ammable gases requires equipment and system designs that mitigate arc fl ash hazards.

Gas

Gas fl ow applications require remote access, control and monitoring the following parameters from the SCADA host:

■ Gas composition and correction factors

■ Meter size parameters orifi ce plate, pipe diameter

■ Availability of production time

■ Measurement history tables

■ Regulatory board compliant meter log

Executing these functions puts many demands on the PLC system:

■ Sophisticated programming is needed, which may take up to 10 minutes to load into a PLC.

■ The PLC helper logic must be able to manage SCADA requests and updates, variable-type conversion, and bit manipulation (masking and packing) for updating meter confi gurations – such as setting the tap location, meter material and triggering read/write commands.

■ The PLC system must be heavily supported by the vendors’application engineers.

20

Schneider Electric value proposition


Schneider Electric’s Merlin Gerin®, Square D® and Telemecanique® brands offer a broad range of power distribution and motor control equipment to maximize SAGD and surface mining operation uptime. This includes:

Medium voltage arc-mitigating andarc-resistant metalclad switchgear

This ANSI/NEMA/IEC switchgear increases uptime because damage is limited when in a fault condition. It eliminates arc and associated hazards via light sensors that activate a fast-acting shorting circuit breaker.

Low voltage ANSI/NEMA/IEC switchgear

This switchgear’s high level of reliability maximizes uptime.

Medium and low voltage Reactivar® power factor correction capacitors

Reactivar capacitors offer operational cost savings, which are achieved through improved productivity, lower utility bills and reduced repair and maintenance costs. They provide voltage support for starting large motors, release capacity (kVA) on transformers and other power distribution equipment, and reduce current losses.

AccuSine active harmonic fi lters

AccuSine fi lters meet the most stringent level of IEEE 519-1992. They can be applied on a common bus, and eliminate the need for harmonics studies. Easily packaged in an MCC, the AccuSine fi lters provide a more cost-effective alternative to using 18-pulse drives as a means to reduce harmonic distortion.

When calculating gas fl ow, the controllers are required to:

■ Perform AGA3 and AGA8 gas fl ow calculations that meet local regulatory requirements

■ Support online changes to the fl ow calculation parameters

■ Historically log data over several days

■ Be API 21.1 audit trail compliant

21

Sepam relays

Their predefi ned, easy-to-set functions facilitate commissioning. They feature Windows®-based software and have a high mean time to failure (over 50 years).

Compact medium voltage motor controllers

Their enhanced safety features include load discharge assembly, compartmentalization, arc-resistant enclosures and grounded isolating switches.

The Motorlogic® Plus 2 solid state overload relay

Its dual Devicenet and Modbus® ports facilitate controlling, programming and monitoring remotely using standard automation equipment. It also allows redundant communication directly to each motor starter. This solution is illustrated on the next page.

TeSys® motor starters

Smart, compact and expandable TeSys motor starters simplify machine customization. The motor starter combines the power, protection and control functions of a conventional motor starter with built-in function blocks and communication functions. Its interchangeable, clip-on components reduce installation time by as much as 80% and inventory requirements by a factor of 10. Its compact size reduces footprint requirements by 50%.

22

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23

Power monitoring and metering systems

These systems integrate the supervision and monitoring of electrical equipment into the DCS environment to help maximize facility uptime and identify opportunities for saving energy. The PowerLogic System Manager Software allows the user to plot historical trends, accurately allocate energy usage, and view power line harmonics.

24

Schneider Electric offers a broad range of automation hardware and software to maximize SAGD and surface mining operation uptime.

Quantum and M340 PLCs and Concept software■ Telemecanique® Modicon® Quantum™ PLCs control primary and secondary

crushers, surge piles, conveyors and hydrotransport pumps for surface mining. They also control utilities, water and sewage treatment plants; Once Through Steam Generators (OTSG); duct burners; and natural gas letdown stations. Redundant Quantum hot standby PLCs provide high availability in harsh environments. For large scale operations, Concept’s derived function blocks (DFBs) provide the ability to standardize programming, which reduces programming time and errors.

■ Telemecanique PLCs calculate steam injection schedules, eliminating the need for additional PCs/computers. This reduces operator hardware costs and increases well site reliability and uptime. Embedding the cycle time calculation for these steam injection schedules in a derived function block (DFB) ensures reliable execution while reducing the risk of the loss of proprietary intellectual property.

Flexible network topologies

Schneider Electric also offers fl exible network topologies – Modbus® Plus or TCP Modbus on a self-healing wire or fi bre optic ring. This solution is illustrated onpage 24 and 25.

Altivar variable speed drives

The broad range of Altivar® variable speed drives and softstarters are well-suitedto the wide range of required motor and conveyor control applications. Theyprovide a high level of reliability and diagnostics (hours of run time and required maintenance schedules).

Transparent Ready®

■ Schneider Electric is the only manufacturer that can link electrical distribution with automation and/control systems, from the service entrance to the fi eld device level, with a complete Ethernet-based solution – Transparent Ready.

■ Customers have easy access to the free, downloadable web page generator tool.

■ Standard, off-the-shelf equipment is easy to install.

■ The Ethernet protocol allows most equipment to be easily integrated intoexisting systems.

■ The embedded web server allows real-time access to power system andmachine control information. This in turn allows the user to customize theircontrol screen and applications.

■ Transparent Ready is easy and affordable. It allows remote monitoring of operations from the downstream distribution equipment entrance to thecontrol room.

25

Prefabricated electrical buildings (PEBs)

Schneider Electric partners with civil, mechanical and electrical companies to custom-fabricate PEBs. These “powerhouses” provide HVAC, lighting, security and motor control for pumpjack operations. They contain Schneider Electric switchgear and motor control centres.

Typical prefabricated electrical building

26

Ethernet

Mine site 1

PC/Concept

Primary crusher Secondary crusher Surge pile Conveyors Secondaryhydrotransport pumps

Local HMILocal HMI Main officePC/Concept PC/Server

Ethernet

System topology for an oil sands mining operation

27

Material Hamdling

Modbus Plusself healingfibre opticor wire ring

Utilities

Modbus Plusself healingfibre opticor wire ring

Main control room

Mine site 2

Ethernet

Ethernet (Radio)

Tailings

Mine control centre

PC PC

BridgeBridge

RadioModem

RadioModem Momentum I/O

28

Gas

Schneider Electric is enhancing existing fi rmware for the M340 PLC to provide AGA (gas fl ow measurement) and API (liquids measurement) fl ow calculation capability. The M340 PLC is being upgraded to include extended temperature (-25°C to +70°C) capabilities.

Local HMI

Schneider Electric AutomationController

Data and Control

Data AGA Calculation PID Loop Control

HistoricalLocal ControlESD

Supervisory System

Control

Pipeline

Temperature Pressure

Gas fl ow control

29

Global Customer References

Onshore extraction projects in Africa

Country Customer/Partner Project name Equipment supplied

Algeria Anadarko/Sonatrach/Brown and Root Condor USA

Hassi Berkine South oil fi eld development

Two prefabricated shelters with MV/LV, switchgears, Fluair 100 and 200 with Sepam, 1 x 7.5 MVA and 4 x 4 MVA transformers – LV Masterbloc and Telemecanique® MCCs, UPS, transformers, revamping

Algeria Anadarko Algeria/Anadarko Algeria

Anadarko Hassi Messaoud oil fi eld development

MV switchgear, distribution transformers

Algeria BP Amoco Algeria/JGC Corp. UK/MW Kellogg USA and UK/Granherne UK

BP Salah gas fi eld project EHV switchgear, distribution products, MV/LV package, switchgear distribution

Algeria NAFTAL/SOCETEC France Tizi Ouzou oil tank farm Transformers, LV switchgear and MCC

Algeria Sonatrach/Agip/BHP Biliton/Saipem/Bouygues Offshore

Rhourde Oulad Djemma oil fi eld (Hassi Berkine basin)

2x 20 MVA immersed France Transfo transformers, 60 kV PS100 substation, 30 x MCset cells for the 5.5 kV substations, SeeFox monitoring and control system

Algeria Sonatrach/Direct order Arzew petroleum site GP2Z – PIC 60 kV/5,5 kV substation

PIC 72,5 kV metal substation: four FA1 circuit breakers, EGIC STR72, 39 Fluair 100 5,5 kV with FG2 circuit breakers, Sepam 2000 protection and control units

Algeria Sonatrach/MHI MCEC Japan/ JGC Corporation Japan

Edjeleh fi eld fl ared gas recovery MV switchgear, LV switchboards and switchgear, distribution transformers

Algeria SONATRACH/SOCETEC/ BOSSARD France

Amassak water Injection MV/LV switchgear and MCC/UPS/transformer

Algeria SONATRACH/SOFRESID France Stah and Edjele water Injection Package/63 kV bay/transformer

Algeria SONATRACH/TOTAL France Rhourd Nouss oil fi elds, Hamra plant

HV/MV/LV substations, additional MV equipment

Algeria Sonatrach Algeria/Bouygues Offshore

Mesdar terminal extension MV switchgear

Chad ExxonMobile USA/KBR USA Esso Chad Moundouli oil fi eld development

2 x 33/132 kV up-step transformers, 3 x 132/33 kV reducer transformers, 2 x 33 kV/400 V transformers, LV substation in a shelter

Chad ExxonMobil/KBR Moundouli oil fi eld 2 x 33/132 kV step-up transformers, 3 x 132/33 kV step-down transformers, 2 x 33 kV/400 V transformers, LV substation built into a shelter

Congo ELF/AGIP/Snamprogetti Italy Elf-Agip Kitina fi eld– terminal extension

MV switchgear

Congo Perenco/Perenco On-shore sites: Tshiende (existing) and Liawenda and Kinkasi (extension)

Two LR71 and 1 x LR101 with transfos and SM6-36 kV

Congo SNEA (P)/SNEA (P) Emeraude Field Electrical and D25 instrumentation shelter

Egypt PETROBEL/PETROBEL Petrobel Aburdis Oil Field (Sinai)

11 kV mobile substation

Gabon ELF/SPIE BATIGNOLLES France Elf Cap Lopez Oil Terminal N/A

30


Gabon Gabon local authorities/AMEC Spie France/Perenco France

Batanga and Echira oil fi elds Electrical distribution

Gabon Perenco Gabon/Perenco Gabon Olende Dome, Niungo and Fernan Vaz (onshore sites)

Control and monitoring system (Seefox EMCS) for supervision of new electrical equipment, LV switchboards (Okken and Prisma MCC), MV switchboards (MCSet and SM6), transformers (12.5 MVA and distribution transformers), revamping of the 20 kV existing main switchboard and of the existing control and monitoring system, cabling studies between our equipment, grounding networks and complete network studies (dynamic stability, coordination, harmonics, fl ows, etc.), installation supervision and equipment commissioning – a large part of the contract fulfi lled by Schneider Greece (Prisma LV switchboards, distribution transformer, SM6 switchboard)

Gabon SHELL/HOLEC Netherlands Shell Rabi oil fi eld Development, section 2

MV switchgear – VM6

Gabon Shell/Holec Netherlands/Fluor UK Shell Gamba oil terminal MV switchgear/SM6

Gabon SNEA (P)/SNEA (P) . Coucal oil fi eld MV switchgear

Gabon Total France/TFE Cert and Sofresid France

Sogara MV extension MV switchgear

Libya Agip Gas BV in Libya/JGC Japon/Bouygues Offshore, France/Tecnimont France/Saipem-HHI Italy/Samsung Eng. Co. Italy/ITD South Korea/Snamprogretti Italy

Wafa and Mellitah shore plants – Western Libyan gas project

MV switchgear, industrial control equipment

Libya Compagnie des Pétroles Total Libye (CPTL)/Joannou and Paraskevaides (J&P), Greece

Mabruk oil-producing site (far west of Sirte basin)

Control and monitoring system (Seefox EMCS) for supervision of new electrical equipment, LV switchboards (Okken and Prisma MCC), MV switchboards (MCSet and SM6), transformers (12.5 MVA and distribution transformers), revamping of the 20 kV existing mains

Libya TotalFinaElf/Compagnie des Pétroles/TotaFinaElf France

TotalFinaElf Mabruk oil fi eld, project 10 CU

Power distribution shelter, transformers, after sales service

Libya Total Fina Libya/Total Fina Libya Mabruk fi eld – phase 2 MV, LV switchboards and switchgear

Libya Total Fina Libya/Total Fina Libya Total Fina Mabruk oil fi eld, satellite 4

Turnkey: Electrical shelter comprising: 20 kV SM6 panel, 4 x 20 kV/100 V transfos, 20 kV/2000V transfo, 1 LV Prisma cubicle, battery chargers, air conditioning, and fi re extinguishing system

Nigeria Elf Nigeria/Mobil Nigeria/NNPC Nigeria/Elf France

Elf Nigeria Kpono waterlift subproject (Benin)

Five cubicles MCset MV switchboards

Tunisia Marathon/Marathon USA Nabeul oil fi eld MV/LV switchgear and MCCs

Tunisia Marathon/Marathon USA Zarzis oil fi eld MV/LV switchgear and MCCs

Tunisia SITEP/SITEP El Borma oil fi eld MV switchgear

Onshore extraction projects in Africa (cont.)

31

Onshore extraction projects in the Asia-Pacifi c region


Australia Nepco/Nepco Nepco transfi eld MV switchgear

China CACT China/Aker Kvaerner Singapore/HHI (Hyundai Heavy Industries) South Korea

Huizhou oil fi eld 19-3,2,1 CACT Operators Group

LV electrical distribution equipment and applications

China CACT/Hyundai/Texaco-Chevron Huizhou Oil Field 19-3,2,1 CACT Operators Group

Four Accusine 300a power correction system units

Indonesia Amerada Hess/Inti Karya Persada Teknik

Ujung Pangkah OPF 1 NEX 24, Motorpact, Blokset, PLCs

Indonesia Pertamina and Petro China/PT Gatra Kilang Persada Indonesia

Centralized distribution power job

MCSet SF6, 13.8 kV-31.5 kA, AD2

Indonesia Total France/Total Indonesia Total Balikpapan retrofi t program LV and MV switchgear

Singapore PTT EP Thailand/Sembcorp Singapore

Bongkot phase 3 C MV switchgear, LV MCCs, distribution transformers, variable speed drives, automation

Thailand Rayong Olefi n Company/Elektro Stoll

Rayong onshore compressor station number 3

LV engineering, Okken LV distribution, MCCs, Sarel frequency converter boards and Altivar® 61 variable speed drives

Vietnam Japan Vietnam Petroleum Co./Worley Ltd

Rang Dong fi eld development Distribution transformers, LV switchgear and switchboards and MV switchgear

Onshore extraction projects in Europe


Czech Republic

Transgaz/Transgaz Transgaz gas pumping station LV products

France Gaz de France/Gaz de France Automation of Saint-Illiers underground natural gas storage facility

34 TSX 7 PLCs, 5 MMX 37 work stations, 29 XBT-V HMIs, 14 Mapway networks

France GdF/GdF Beynes gas underground storage

Supervision and control system

France GdF France/GdF France GdF Etrez underground gas storage

Safety Automation: Study, safety system supervision, switchboards

Hungary Rt. Dunamenti Eromu Rt./Szavill Kft.

Strategic oil storage tank Electrical equipment installation, MV/LV switchgear and MCCs

Netherlands Shell/Comprimo Netherlands Shell oil fi eld, section 1995 MV switchgear and MCCs

Russia Gazprom/Electrogaz Gasprom Orenburg oil fi eld – MV/LV substation revamping

LV switchgear and MCCs/MB200-MB400, Fluair 200/ISIS 3000 MV switchgear

Russia Gazprom/Machinoimport Russia Gazprom – gas production and pumping

14 Sepam supervisory systems

Russia Neftegaz/Machinoimport Russia Surgout oil and gas fi eld MV switchgear

Ukraine Odessa Oil Terminal/Local Odessa oil terminal Four bays 110/10 kV GIS substation, ISIS 200 monitoring and control

32

Onshore extraction projects in the Middle East


Iran IOOC/IOOC Sirri fi eld MV switchgear

Iran National Iranian Oil Company/Thermo Design Engineering, Canada

Shanul gas fi eld 35 MCSet anti-seismic cubicles, 26 Okken cubicles, LV busways

Iran NIOC/John Brown GB Aghar Dalan gas fi eld MV switchgear, spare parts, transformer

Iran Petroleum Development and Engineering Co., Iran/HDEC South Korea

South Pars fi eld development – phases 2 and 3

Distribution transformers (France Transfo): power transformers and oil dry transformers

Iraq NOC/Mannesmann Germany Saddam oil fi eld MV and LV switchgear and MCCs

Iraq NOC/Technip France Khabbaz oil fi eld MV and LV switchgear and MCCs

Iraq Parsons Iraq joint venture (for South Oil Co)

Cluster pump station number 10 – renovation

MCset 6.6 kV, OKKEN 400 V with distribution transformers

Kazakhstan Hurricane Kumkol Munai JSC Canada/Kaz NIPI Energoprom Kazakhstan

Kyzyl-Ordra oil fi eld 26 x 55 kV ATV58 variable speed drives (with standard enclosures + accessories), 30 x 90 kV ATV68 variable speed drives (with 30 x IP54 enclosures) and 1 x 6 kV distribution switchboard with 27 MCsets and Sepam 2000

Kazakhstan Tengizchevroil Project SGP 12 AccuSine 300A power correction systems for 690 VAC

Qatar ELF Petroleum/NPCC (UAE) Elf Al Khaleej fi eld development 22 kV switchgear, capacitors

Qatar Qatar Petroleum/Imco Qatar GTC 121 49 MCSet cubicles

Qatar Qatar Petroleum Dukhan/Danway Qatar petroleum Dukhan fi eld support area

40 AD1 and AD2 panels and 12 kV MCset

Qatar Qatar Petroleum Dukhan/Voltage Engineering

Qatar petroleum Dukhan gas stripping plant

27 AD1 and AD2 panels and 7.2 kV MCset

Qatar Qatargas/Technip France/Mc Dermott U.K./TEC Japan/Toyo Engineering Japan/Chiyoda Corporation Japan

Qatargas upstream development

Turnkey MV substations: 33/6 kV switchgear, transformers, LV switchgear and MCCs, 400V switchgear automation/LV revamping, Electrical Control Systems – ISIS 3000, PRISMA panel, LV smart switchboard

Qatar QGPC/Quantel Canada Dukhan powered water Injection MV and LV switchgear

Qatar QGPC/SICON Oil and Gas Ras Abu Fontas gas fi eld 3.3 kV switchgear

Qatar QGPC/TECHNIP France – Flakt/Bechtel UK/Sambawang Singapore

Umm Said north fi eld development

33/11/3.3 kV switchgear and MCCs, LV switchgear and MCCs

Qatar QGPC Qatar/Elequip GB Dukhan fi eld tank vapor blower 33/11/3.3 kV switchgear and transformers

Syria AL Furat Petroleum/TPL Italy Omar oil fi eld MV package – 66/22 kV substation

United Arab Emirates

ADCO/Stone and Webster GB/Babcock Electric GB

Adco Bu Hasa water injection and power upgrading Exploration 1 and 2

MV switchgear, MV extension


ADCO/Snamprogretti Italy ADCO Sahil fi eld development Fluair 100, modifi cation of Fluair 400, Bus duct, 33/11 kV switchgear


TotalFinaElf Qatar/Technip UAE /NPCC UAE/McDermott UAE/Sofreside France/Hyundai South Korea

Elf Al Khaleej fi eld development – phase 3

LV switchboards and switchgear, MV switchgear and distribution transformers


ADNOC KSA/Snamprogetti Italy Jarn Yaphour fi eld MV switchgear

33

Onshore extraction projects in the Middle East (cont.)

Country Customer/Partner Project name Equipment suppliedUnited Arab Emirates

ADCO UAE/Veco Corp USA/Technip France

NEAD (North East Abu Dhabi) project

MV switchgear


ADCO (Abu Dhabi Company for Onshore Oil Operations)/Technip-Cofl exip (in partnership with National Petroleum Construction Company (NPCC), Abu Dhabi

North East Bab (NEB) project – Al Dabb’iya and Rumaitha oil fi elds (production capacity increase)

MV switchboards – 75 MCSet 1-2 (11 kV) cubicles with SEPAM protection units – 15 Sepam, Sepam series 40, 80 and 75, control and monitoring contract (SEEFOX system)


Qatar Petroleum Dukhan/Medgulf Qatar Petroleum Dukhan water injection plant

50 AD1 and AD2Panels, 7.2 kV MCset


Zadco/NPCC/Technip (UAE) Zadco Zirku gas fi eld MV switchgear and MV motor replacement

Onshore extraction projects in North and South America


Argentina Total Austral Argentina/TotalElfFina France

Total Austral oil fi eld – extension LV switchgear

Argentina Total Australia/Propak Systems Total Canadon Alfa downstream gas fi eld project

MV/LV switchgear and MCCs, transformers. MCset switchboard and transformers for an LNG plant extension in the austral cone

Brazil Petrobras/UN-SEAL Carmopolis – Sergipe – seven wells

ATV 71 drives, Twido PLCs, LC1 contactors, GV2 manual motor controller, RM4 relays, ABL7 power supplies, 174CEV Ethernet/Modbus bridge

Brazil Petrosynergy Petrobras (UN-SEAL)/Alagoas State TM21 onshore well automation

Seven ton Vulcan pump unit, 20 Cv GE motor, ATV 71 drives

Brazil Petrosynergy Petrobras (UN-BA) Bahia State Onshore well control

Blokset MCCs

Canada Braceworks Automation Zelio relays, Square D® moulded case breakers, operator disconnects, Square D push buttons

Canada Chevron Canada Crude oil pumps AccuSine 300 amp power correction system units

Canada Crestar Crude oil pumps AccuSine 100 amp power correction system units

Canada Devon Energy Jackfi sh Lake PLCs

Canada Duke Energy PLCs

Canada Encana Foster Creek MV and LV switchgear, MV and LV MCCs

Canada Husky Oil Lloydminster PLCs

Canada Imperial Oil Cold Lake PLCs

Canada National Oilwell Corlac Square D moulded case breakers, operator disconnects, Telemecanique® 22mm push buttons, selector switches and pilot lights

Canada Nexen PLCs

Canada Petro Canada MacKay River PLCs, MV and LV switchgear, MV and LV MCCs

34

Onshore extraction projects in North and South America (cont.)

Canada Shell Canada Peace River PLCs

Canada Suncor Energy Ltd. Fort MacMurray PLCs, LV switchgear, power distribution panels

Canada Shell Canada Caroline, Alberta/Shell Canada Caroline, Alberta

Shell Canada Caroline gas production and processing facility

Modicon® 984, Modbus® Plus Communication Network

Canada Syncrude Fort MacMurray Concept software, Quantum™ and Momentum™ PLCs

Canada Weatherford EP Solutions Square D® moulded case breakers, operator disconnects, Telemecanique® 22mm push buttons, selector switches and pilot lights

Colombia BP Amoco/BP Amoco BP Araguaney pumping station Variable speed drives and LV distribution equipment

Colombia BP Colombia/Techint Colombia BP Coveñas on-shore UPS

Colombia British Petroleum GB/BP/Fluor Daniel GB

BP El Porvenir oil fi eld – pumping station

Outdoor substation with 34.5 kV cubicles. F200, protection and control elements, installation and commissioning

Colombia British Petroleum GB/British Petroleum GB

BP Cusiana oil fi eld MV and LV switchgear

Colombia British Petroleum GB/Parsons and Whittemore U.S.Am.

BP Cusiana oil fi eld, CPF 2 Transformer, busway

Colombia Houston Oil Co./Columbia (HOCOL)/HOCOL

Neiva oil fi eld – gas turbine protection 2 x 3750 kW

Design and supply: 13.2 kV metalclad substation, auxiliary services and MCCs, startup service, cables, installation supervision, battery and charger

United States

Koch U.S.Am./Koch U.S.Am. Pine Bend crude pump ND

Venezuela Lagoven/Sadeven Lagoven oil fi eld Turnkey 230 kV/115 kV substations, power transformers

Venezuela Total Elf Fina/River Consulting Columbus Ohio, USA

Sincor upstream project Set of seven shelters to equip seven wellhead clusters


35

Glossary of Terms

API American Petroleum Institute scale of gravity – the lower the number the thicker the oil.

Acidizing The injection of acids to dissolve channels in the formation rock around the well.

Artifi cial lift When formation pressure is not suffi cient to force the liquids to the surface, the production of oil and gas will require pumping.

Blowout preventer A valve to protect crews and equipment from a sudden increase in downhole well pressure, a.k.a. a Christmas tree.

Cogeneration The use of waste heat for electricity generation.

Coke A byproduct of bitumen upgrading.

CMB (coal bed methane)

Methane trapped within coal beds.

Completion The process of preparing the well for production after a well bore is drilled and cased.

Cyclic steam An in situ oil sands bitumen recovery method, which uses the same well to pump steam into the ground and later to pump the bitumen to the surface.

Christmas tree See blowout preventer.

Dewatering If methane is associated with water in a coal seam, water has to be removed from the well before methane production can begin.

Directional or horizontal drilling

Drilling a well bore by steering the bit underground.

Downhole motors Equipment used to drive a drill bit by circulating mud.

Drilling rig Machinery used for drilling wells.

Drillstem The pipe that houses a bit used in drilling wells.

Drillstem test Test used to determine the fl ow rates and composition of a hydrocarbon deposit prior to production.

Fire fl ood An in situ oil sands bitumen recovery method in which oxygen is injected and part of the resource is burned in order to liquefy the bitumen for extraction.

Fracturing or fracing The injection of high-pressure water or oil to create cracks in the rock formation.

Frontier plays Exploration for petroleum in remote areas.

Heavy oil Thicker grade of oil commonly used in asphalt road construction but also for upgrading into lighter petroleum products. Heavy oil sometimes requires the addition of condensates to be able to fl ow through pipelines. Heavy crudes are considered as 22.3 degrees API or less.

36

Heavy oil differential

The difference between the lower priced heavy oil and the price of lighter crude.

Hydrocracker A chemical reactor where large hydrocarbon molecules are fractured into simpler molecules in the presence of hydrogen.

Hydrotransport An oil sand and water slurry carried by pipeline to a processing plant.

Infi ll drilling Increasing the number of wells between existing wells to improve production.

Integrated oil sands projects

Combined bitumen extraction and upgrading processes on the same site.

Iron horse The familiar well pump seen around world.

Mud A mixture of clay, chemicals and water that circulates through the drill bit to lubricate and cool the bit, remove rock cuttings, stabilize the wall around the hole and control the pressure in the well bore.

Natural gas from coal (NGC)

see CMB (coal bed methane)

Perforating gun An explosive device lowered into a well bore to the depth of the producing formation, which is then detonated to puncture the casing cement to allowoil or gas to fl ow into the well.

Programmable Logic Controller or Programmable Automation Controller

Programmable computer designed to control industrial processes.

Rotary drilling rig A modern drilling rig.

Sour gas Natural gas containing H2S. “Sour” refers to the sulphur content.

Surface casing The steel pipe at the top of a well to keep the wall from caving in.

Top drive A drill rig innovation that uses an electric orhydraulic motor at the top of a drill stem insteadof a rotating table.

Underbalanced drilling

Using mud lightened by nitrogen or other gases to minimize damage to the producing reservoir bydrilling fl uids.

Vapex An extraction method that uses natural gas liquids such as propane and butane instead of steam to free bitumen from oil sand.

Well stimulation Improving production from a well by injections of acids, gases, high-pressure water or oil andother techniques.

37

Notes

38

Notes

Schneider Electric Industries SAS

Address: F-38050 Grenoble cedex 9FranceTel: +33 (0) 4 76 57 60 60

http://www.schneider-electric.com

As standards, specifi cations and designs change from time to time, please ask for conformation of the information given in this publication

Publishing: Schneider Electric Industries SASCover page design: n.b. nota benePhotos: image bank, Schneider ElectricPrinting: Imprimerie du PONT DE CLAIX

this document has been printed on ecological paper.

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ART960148 05/2007

onshore extraction application guide

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