SCADA System for Oil Pumping Rig RTUs

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"Thanks to the flexibility of LabVIEW, we significantly increased energy conversion efficiency, prevented oil well failures, and generated oil and gas production statistics. We developed a permanent monitoring and control system for the technological processes of downhole equipment in real time."

- , Ovak Technologies, Naftamatika

The Challenge:
Developing a supervisory control and data acquisition (SCADA) system for 10,000 remote terminal units (RTUs).

The Solution:
Using LabVIEW to develop a SCADA system to diagnose, monitor, and control technological processes of downhole equipment in real time.

Author(s):
- Ovak Technologies, Naftamatika

Company and Project Background

Naftamatika offers modern, efficient, and proven solutions for producing oil wells. The company develops and produces unique automation equipment for oil production. Ovak Technologies, an NI Silver Alliance Partner, specializes in embedded control and delivers a variety of engineering services such as software engineering, hardware design, algorithm engineering, algorithm implementation, and field test services for specific industry problems.

The SCADA Solution

Ovak Technologies developed the software based on the technical specifications of Naftamatika. SCADA universal software collects, organizes, and analyzes data coming from remote rod pump controllers and any other oil field objects like pump stations. The system delivers full well control and contains modern software for analysis of all parameters for each well.

Figure 1. SCADA Topology

SCADA can prevent oil well failures, increase energy conversion efficiency, and generate oil and gas production statistics. The system consists of a server that collects and stores information, and a client that allows the user to interact with the rest of the system. The server has several layers of operation:

  • Periodic data acquisition from RTUs upon expiration of specified time
  • Data acquisition from RTUs upon user request
  • Configuration and technological process data storage and fetching from a Microsoft SQL database
  • Analyzing collected data from RTUs
  • Providing multiuser and multilevel access to the server functionality

The web client offers an opportunity to connect to the server through the web and manage, control, change, view, and analyze data and existing RTUs under system. Users can select the well and perform several types of analysis over that well to determine the cause of any existing problems. The user can view historical trends of parameters collected from the server from the web client to determine changes in technological processes.

The system periodically reads technological process data from 10,000 RTUs using several types of communication drivers/protocols such as: Modbus over serial interface, Modbus over TCP, and OLE for Process Control (OPC) Client. The data is saved in a Microsoft SQL database. The system features the following functionalities:

  • Several levels of security and user access
  • Database management
  • Well tree organization by group
  • Well analysis
  • Well operation mode change
  • Folder management (create, rename, delete)
  • Well management (create, rename, delete)
  • Alarm history
  • Parameter graph review
  • Alarm identification
  • Historical information display for each parameter
  • Multiple trends display over each other as graphs or tables
  • Register scanning and storage as a group
  • Display of the same parameters of several wells in a table (group view)
  • Well parameter management (read, write)
  • Binding controller’s Modbus registers with OPC tags
  • Database connection configuration
  • Service configuration (install, remove, start, stop status)
  • User access configuration
  • Display of all registered users list
  • Serial port parameter configuration
  • Ethernet port configuration
  • Date and time synchronization
  • Custom comments option for the wells
  • Surface and downhole card retrieval
  • Multiple card overview
  • System analysis review
  • Automatic card receiving in specified time interval
  • Card storage with date and type
  • Data retrieval from other system databases
  • Use of other OPC servers as data source for a particular well
  • Tags hierarchical display
  • Implementation of T-SQL query from web GUI
  • OPC support
  • Configurator activity log
  • Task scheduler
  • Display of all configuration ports
  • Historical information lifespan configuration
  • Well status parameters achieved
  • Card lifetime configuration on server
  • Templates for tags
  • Report generation

Analysis Module

  • Dynamometer card analysis
  • Wattmetrogramm calculation
  • Typical card comparison
  • Rod 3D analysis
  • Well operation diagnosis
  • Theoretical card calculations
  • Production calculation
  • Surface equipment loading calculation
    o Gearbox loading
    o Structure loading
    o Rod taper loading
  • Leakage calculation
  • Energy consumption calculation
  • Pump efficiency analysis
  • Pump intake pressure calculation
  • Surface and downhole card formation
  • Position calculation based on equipment geometry
  • Well balancing information calculation
  • Downhole pumping equipment diagnostics
  • Power consumption calculation
  • Friction force calculation from well deviation survey

Graphical User Interface (GUI)

The system includes a web-based HTML GUI so users can access the system from a remote computer using any Internet browser. Users can also access the full assortment of functions and historical data through mobile devices.

While running the GUI from a workstation on a network that links to the host computer, the user does not see any part of software other than the HTML GUI. In addition, users can run the client application on the same computer that the server is running on. Whether the client interface runs on the server computer or on a separate workstation, its function is the same: it provides the user with a means to communicate with well controllers or other devices, review dynamometer cards and analysis, and enter and retrieve data.

Figure 2. GUI

System Advantages

  • Increase in production effectiveness
  • Simplification and acceleration of change, update, and modification procedures
  • Detailed reference material
  • Openness and compliance with standards provides interaction with other programs by means of OPC, OLE database, and Open Database Connectivity technologies
  • Context help
  • Simple to learn
  • Object-oriented approach
  • High data throughput of communication channels
  • Data storage in case of alarms and system failures such as software failure, data transmission network failure, or power supply system failure
  • Unlimited data lifespan
  • Data retrieval for 20 parameters from 3,600 units during an hour
  • Individual setting storage
  • Data export to Microsoft Excel, Microsoft Word, and Adobe Reader
  • Support for up to 10,000 controllers
  • Support for up to 5,000 clients

Conclusion

Thanks to the flexibility of LabVIEW, we significantly increased energy conversion efficiency, prevented oil well failures, and generated oil and gas production statistics. We developed a permanent monitoring and control system for the technological processes of downhole equipment in real time. 

Author Information:

Ovak Technologies, Naftamatika
info@ovaktechnologies.com

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