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of Saudi Aramco.

Pablo Genta March 27-30, 2012

7th Pipeline Technology Conference 2012

Outline

• Introduction

• RTTM Saudi Aramco scenario

• RTTM Safety and Integrity Data Model

• Technology Implementation Model

• S&I RTTM challenges under “real-life”operation

• Practices & Accomplishments

– Technology screening,

– Engineering Design,

– Testing & Commissioning

– Operations and Maintenance Infrastructure

• RTTM…what it really takes

• Conclusions

2

RTTM Introduction

Q Q P P T T

Pipelines RTTM

Pipeline/s

Other Systems

Estimated Process

Variable & Deviations

Function Specific Results

Estimated Fluid & Pipe

Parameters & Deviations

Leak Detection Batch Tracking Scraper Tracking Inventory

Calculations Operation

Deviation Alerts Corrosion

Forecasting

Basic Functions

Advanced Functions

RTTM Introduction

• Basic Functions- Process Variable Estimators

– Overall accuracy : “instrument-sense” overall accuracy

– Model Stability: convergence at various operations and data-flow scenarios

– Overall model uncertainty: “reality vs. reality-like equations”

– Robustness: ability to perform in absence of data

– Reliability: cumulative errors over a predetermined period of time

• Advanced Functions – Software engine

– All of the above for the software engine

– Susceptibility: operating conditions-derived uncertainties

Reality is not linear, uncertainty either….

4

RTTM on Saudi Aramco Pipelines

• Large-scale pipeline operations more than 350

pipelines

• Large flow-rates exceeding millions of barrels per day

per lines

• Large capacity pipeline network and large pressure

and flow control facilities

• Built-in redundant Pipeline network topology

• Rapidly growing transporting network

• Multiple hydrocarbon supply interconnected facilities

• Multiple fluids transported, natural gas, various crude

oil bends, NGL, condensates, various types of

products

5

SHARED DEVICES

RTTM Only

RTTM Only

FULLY INTEGRATED

SHARED

PARTIALLY INTEGRATED

SHARED

STAND ALONE

OTHERS HARDWARE RTTM RTTM

SHARED DRIVERS

RTTM DRIVER

RTTM DRIVERS

SCADA SCADA

RTTM APPLICATIONS RTTM

APPLICATIONS

RTTM on Saudi Aramco Pipelines

RTTM Data Flow Model

Field Instrumentation

Data Acquisition

Early Data Processing

RTTM RTTM Engine

Emergency

Response

Leak

Detection

and

Location

Operation

Deviation

Alert

Systems

Corrosion

Monitoring &

Forecasting

Cleaning

Scraper

Tracking

“What-If”

Simulation

DOC’s

Growing Requirements

DB

Engineering

Operation and Maintenance

Manager

Technical Support

Equipment

Monitoring

RTTM Implementation Model

8

Identify Need

Assess Technology

Performance

Current Practices

Acceptable

No

Yes

Apply Develop

Select Cost-

Effective

Technology

Execute Project • Identify Target

Facilities

• Cost-Benefit Analysis

• Implementation

Guidelines

• Standardization

Screen

Technologies/

Methods

Does current practice

meet

Performance level?

Categorize Selected Technology based on

Priority and Maturity

Does the selected

Technology meets required

Performance?

No

Yes Go to Step

1

Pilot Test

In-House

Expertise

Step 1 Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Step 10

RTTM Pipeline Safety Leak Detection and Location

9

RTTM LDS Performance

Screen Pipelines Current Methods

Acceptable

No

Yes

Determine

Min Leak-Size to

Detect

Determine

Detection-Time

Determine Max

Tolerable Leak

Volume

Determine Required

LDS Performance

Conduct

Risk Assessment

Severity of Impact

Does Current

LDS Reduce Risk to

Acceptable

Level?

Determine Leak Flow & Response Time

Proximity to

Coastal Areas

Proximity to

3rd Party Assets

High Toxicity & Flammability

Local

Regulations

Diameter

Proximity to Populated Areas

Pressure Flow Rate

Screening Factors Selected by PD, LPD & EPD

RTTM Performance

Product vs Requirements QRA-Based

11

0%

10%

20%

30%

40%

50%

5 min10 min

15 min30 min

1 hour2 hours

4 hours

Required Performance

Product Performance

RTTM LDS under real-life operations

12

Trunk line high flow- rate : 1800 MMSCFD, supply pressure from 1321 psig to 1017

psig and flowing temperature of 104 °F equipped with flow meters of +/- 36 MMSCFD

(42480 m3/h) . Calculated density ranging between 80.2 kg/m3 to 62.9 kg/m3 [3].

Pressure span of 2071 psig (142.8 barg), an accuracy of +/- 0.107 barg. Assuming

steady state conditions, repeatability of +/- 1%. This yields +/- 18 MMSCFD volume

uncertainties for the trunk line. Statistically independent, total flow meter error of +/-

25.5 MMSCFD.

Overall uncertainty during steady state operation of +/- 29.3 MMSCFD.

During non-stationary operation repeatability is replaced by accuracy, the uncertainty

reaches +/- 58.5 MMSCFD which is 3.63% of the nominal flow-rate.

Without taking into account errors in the RTTM model including heat transfer during

transients

In practice, overall uncertainties in transient conditions far exceeding 5%

16” Single Phase Gas Pipleine

Recording Time Frame 12:11:41.531 Hs – 12:13:20.291 Hs

13

Challenging Leak-like buried transients

RTTM LDS under real-life operations

GOSP-3

GOSP-1

GOSP-2

GOSP-4

ABQ

46” Crude Oil

30” Crude Oil

Length = 640 km

WT = 0.42” to 0.625”

MAOP = 815 psig

Length = 223 km

WT = 0.375”

MAOP = 1135 psig

KM8 KM211

RTTM LDS under real-life operations

DRA Injection

DRA Injection

30” Single Phase Crude Oil Pipleine- DRA Injection

Calculated

Uncertainty

15

DRA injection

MAOP = 815 psig

RTTM LDS under real-life operations 30” Single Phase Crude Oil Pipleine

16

High frequency pressure fluctuations under buried in low frequency transients.

RTTM LDS under real-life operations

Practices

17

RTTM Product- Application

• Gap Analysis : RTTM Optimum Scenario vs

Application Scenario

18

0

10

20

30

40Fluid GTL %

Line design

P,Q LevelTransientSeverity

Infrastructure

Readiness

Application Scenario

RTTM Optimum Scenario

Will we succeed?

Do we really know this RTTM too?

Technology Screening Practices

19

Benchmark Software Simulation Process dynamics identification

Generating process dynamics through FFT composition

Process dynamics generator validation

Injecting process dynamics into RTTM to test functionalities, e.g. leak

detection, pressure cycling, model fitness under transient conditions

Process dynamic generated signal

20

Average Signal

Benchmark Software Simulation 36” Single Phase Crude Oil Gathering Pipeline

Generating Realistic Transient

Scenarios

Technology Screening Practice

UP1,2

UT1,2

U Qv

Uρ

UФ

Total U Q U Line Fill

U Length

U Roughness

U Pipe Wall

U

Expected Sensitivity &

Accuracy

ISO 5168

ASME PTC 19.1 & 2

Model Uncertainty

Infrastructure

EXPECTED PERFORMANCE

at REAL-LIFE CONDITIONS

Performance Study

Assessment real-life comm round-trip delay+latency+bandwidth+ availability

Engineering Practices Baseline RTTM Model Uncertainty Analysis

Engineering Practice

• Field Device Infrastructure for Time-Sensitive Data Flow

– Minimum Availability 99.9% for RTU’s

– Minimum Availability of 99.999% for communication links

– Field Data buffering, “store and pull” strategy

– Time synchronization through GPS

– Distributed data processing function-specific, field processors

– Built-in RTU diagnostic for communication ports with port auto-reset

– Minimizing field throughput demand through optimizing field processing functions

– Requirements for handling

22

Test Practices

38

39

40

41

42

43

44

11

40

82

81

54

22

25

62

97

03

68

44

39

85

01

12

57

12

66

41

40

71

15

47

81

68

85

18

29

21

96

99

21

10

62

25

13

23

92

02

53

27

26

73

42

81

41

29

54

83

09

55

32

36

23

37

69

35

17

63

65

83

37

99

03

93

97

40

80

44

22

11

43

61

8

Establishing Baseline Performance at operating conditions – “Understanding your Process” Example: Determine Minimum Detectable Leak in crude oil lines under real-life operations. Observability

Actual Leak 2” on 24” Crude oil line

low pressure

Spectrogram Actual Leak 2” on 24” Crude oil line low

pressure in benign hydraulic noise conditions

Test Practices

Establishing Baseline Performance at operating conditions – “Understanding your Process”

Example: Determine Minimum Detectable Leak in crude oil lines under real-life operations. Observability

24

Sudden Leaks 3/4” simulated on 16”

gas pipeline measured at 19 km

from leak point

RTU

RTU

RTU

Maint. Center (Abq)

Maint. Center (DH)

Maint. Center (PS-6)

Distributed Architecture

Optimum Performance

Effective O&M

Sensible Resource Allocation

Infrastructure

Resources Overview

what it takes…. • Technology Screening, Development and Pilot-Testing

– Reliable and valid supplier’s past test records supplier openness

– “Realistic” model specifications supplier openness

– “Real-life” testing platform or reliable software-based tools

• Engineering Design

– Engineering Best-Practices , Industry Standards poor or inexistent

– Data acquisition and

instrumentation time-performance data poor or inexistent

• Infrastructure

– Real-time field availability and reliability careful assessment

– Application-oriented instrumentation sometimes underdeveloped

– Remote monitoring facilities geographical resource allocation

26

Conclusions

• S&I RTTM Performance means understanding process and technology limitations

• RTTM sustainability implies best-fit infrastructure & data-flow architecture

• Poor Industry Standardization

• Limitations against expected benefits ……can we achieve watch-maker accuracy using stone-age tools?

• Understanding your RTTM tool through valid supplier data is a must

• High potential platform

27

Thank You

28