Presentation

Oil & Gas Conference
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Presentation
• Title: S7-400H and Comfort Panels Supply the Perfect Distributed
Architecture for a Drill Rig Mud Mixing and Bulk Handling System
• Presenter: Wilson Santamaria
• Company: Champion Technology Services, Inc.
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Presenter - Wilson Santamaria
Wilson has been an Automation Engineer at Champion for over three
years. He began his career as a Process Engineer at a major
manufacturing company in El Salvador.
At Champion, Wilson is responsible for designing, implementing, and
managing complex control systems. His extensive experience includes
process control and automation engineering for the Oil & Gas and
Chemical industry.
Wilson has a Bachelor of Science degree in Chemical Engineering from
the University of El Salvador and secured his Master of Engineering
degree in Chemical Engineering from Lamar University.
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Champion Introduction/Overview
• Champion Technology Services, Inc.
• Founded in 2000 with a main focus in industrial
automation and control systems integration
• Focus now includes wireless communications
and data management
• Most automation projects include the design,
fabrication, integration, installation,
commissioning, and follow-up maintenance of
control systems
• 130 employees
• 8 offices in 4 states
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Champion Introduction/Overview - Continued
Siemens Solution Partner
• Primary markets served:
• Oil & Gas (upstream, midstream and
downstream)
• Chemical
• Metals
• Mining and minerals
• Pulp and paper
• Food and beverage
• Marine
• Utilities
Services for the following:
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DCS and hybrids
PLC
SCADA and HMI
Panel design, drafting, and fabrication
Alarm management
Historians
Information systems
Safety systems
Legacy migration
RTU and flow computers
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SUPPORT CAPABILITIES
• Staff of 90+ Automation Specialists
• Specialize in Oil & Gas and Chemical applications
• Expertise and experience in most major control systems
• Front End Engineering and Detail Automation Design
• 24 hour local support
• Customer service is unparalleled across Gulf Coast and Rocky Mountains
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Proven Technologies and Shell Introduction/Overview
• Proven Technologies, LLC
• Shell Oil Company
• Original equipment manufacturer (OEM)
that supplies systems for oil and gas
customers
• Industries served:
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• Oil and gas
• Bulk solids transfer
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• Slurry blasting
• Water reclamation
• Oil platform in the Gulf of Mexico
• Oil production for energy demand
Upstream - Explores for and extracts crude
oil and natural gas
Downstream - Refines, supplies, trades and
ships crude, manufactures and markets a
range of products, and produces petrochemicals
for industrial customers
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Olympus Mars B Offshore Platform
Type: Tension Leg Platform (TLP)
Location: Gulf of Mexico
Depth: 3,000 feet
Interests: Shell (71.5%) and BP (28.5%)
Field: Mars
Production: 100,000 bpd
Builder: Nabors Drilling, Baytown, TX
Sailed: October 2013, Ingleside, TX
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Business Challenges
• Setting up and validating the piping arrangement
• Manual system caused piping and tankage system errors
• Loss of production
• Downtime caused by cleanup
• Personnel involved in cleanup removed from core functions
• Quality control
• Ease of diagnostics
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Process Overview
TRIP TANKS SYSTEM
NORTH
UPPER LEVEL
MUD GAS SEPARATOR
GUMBO BOX
SOUTH
BELL NIPPLE
TO
SHAKERS
TO MUD
PROCESSING TANK
DRILL FLOOR
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Champion Solution Overview
• Solution
• Automation system for a drilling rig mud mixing, bulk handling, and trip tanks system
• Involved integrating three separate drill rig modules (bulk handling, mud mixing, and
trip tanks) that were manually operated and operated independently
• System Architecture
• S7-400H system with eight remote I/O racks
• Three comfort panels
• Optical link modules with ring topology
• TIA Portal
• SIMATIC Manager
• Redundant Profibus for master, slave, and HMIs
• Modbus TCP communication to proprietary client rig software (RigWatch)
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Design/Installation
• I/O capability of approximately 1,500 I/O
• Operator Stations
• One door-mounted Siemens TP2200
• Initial Design
operator station at the trip tanks
• Reviewed P&IDs
• One pedestal-mounted Siemens
• Panel design completed at Champion’s
TP2200 at mud mixing
• One door-mounted Siemens TP2200
Sulphur, LA office
• Automation hardware and topology
operator station at the vacuum
reloader
design
• Automation Hardware
• Redundant 414H processors
• Development
• Redundant IM 151-2 at each of the
• P&ID development, setup, and
eight racks (tied to OLMs)
configuration of the system
• ET200M I/O
• Extensive use of experienced resources
• Historian (Nabors RigWatch using
familiar with mud mixing and transport
Siemens’ S7-400 Modbus TCP
• Creation of graphics
communications blocks
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Design/Installation - Continued
• Fabrication
• One trip tanks system enclosure
housing the redundant CPU and one
remote I/O rack
• Two mud mixing system enclosures
housing four remote I/O racks
• Two vacuum reloader system
enclosures housing three remote I/O
racks
• One pedestal-mounted HMI panel
• Training
• Operator/maintenance—conducted on
the platform
• Commissioning
• Commissioning/cutover completed
over two months of offshore work
• Factory Acceptance Test
• Conducted at Champion’s office in
Houston, TX
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HMI Graphics
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System Architecture
TRIP TANKS PANEL
PRL CPU SEC CPU
RACK
RACK
OLM
“A”
OLM
“B”
RIO #1
MUD MIXING PANEL #1
HMI PANEL
OLM
“C”
RIO #2
OLM
“A”
RIO #3
OLM
“B”
MUD MIXING PANEL #2
RIO #4
RIO #5
HMI
PEDESTAL
VACUUM RELOADER PANEL
HMI PANEL
OLM
“C”
RIO #6
OLM
“A”
RIO #7
OLM
“B”
RIO #8
HMI PANEL
OLM
“C”
FIBER
COPPER
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Realized Benefits
• Siemens TIA Portal/WinCC professional faceplates implementation
• Ease of future additions
• Time saving
• Standardization
• Ability to view alarms for all three systems from all HMIs in different areas
• Enhanced safety
• Reduced troubleshooting time for maintenance
• Siemens S7-400 continuous monitoring of all the alarms and instruments by
RigWatch via ModbusTCP communication
• Enhanced flexibility to operate entire system in three different modes: Auto,
Remote/Manual, and Local Manual
• Automatic switchover of the redundant CPUs in the event of a failure without effecting
the operation in Automatic or Remote/Manual (extremely important specially during
the mud transport operations)
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What’s Next
• Remote communications
• Historian
• Ongoing support
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Thank You For Attending
Questions?
More Information?
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Wilson Santamaria
Houston Automation Engineer
More Information
Contact Rama Sinha – Business Manager
Email: Rama.Sinha@champtechnology.com
Phone: (281) 537-7366
HEADQUARTERS: 11824 MARKET PLACE AVENUE | BATON ROUGE, LA 70816 | U.S.A.
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