Fault detection and diagnosis in fiscal metering stations using … · 2019-05-27 · Fiscal...

Fault detection and diagnosis infiscalmetering stationsusing canonicalvariate analysis

AfrânioMelo1,Nayher A.Clavijo Vallejo1,MaurícioM.Câmara1,ThiagoFeital1,ThiagoK.Anzai2,PedroH.Thompson2,FábioC.Diehl2 and JoséC.Pinto1

1- ProgramadeEngenhariaQuímica/COPPE– UFRJ- UniversidadeFederaldoRiodeJaneiro.2- CentrodePesquisasLeopoldoAméricoMiguez deMello- CENPES,Petrobras- PetróleoBrasileiroS.A.

CidadeUniversitária,RiodeJaneiro,Brasilafranio@peq.coppe.ufrj.br

Outline

• The context: fiscal metering;

• The system:AMP, a sytem for process monitoring;

• The application: the metering station;

• Results;

• Conclusions.

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

ThecontextFiscalmetering

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Fiscalmetering

• Fiscal meters are one of the most crucial equipments of a process plant.

• Values related to royalties, allocation and custody transfer depends on them.

• Small errors in measurement can lead to large losses in revenue.

• Thus, accuracy plays a very important role in their operation!

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Fiscalmetering

• Flow measurements are constantly supervised by governmental regulatoryagencies.

• The agencies establish protocols that must be followed in order to notifyabnormalities.

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Fiscalmetering

• Below we have the protocol imposed by ANP (Agência Nacional do Petróleo,Gás Natural e Biocombustíveis):

• once a fault is identified, an official notification must be sent to the regulatory agencywithin 72 hours;

• the problemmust be fixed in a 240 hours limit;

• after this limit, the fiscal meter could be put out of operation - which would lead to a greatimpact in terms of production.

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Fiscalmetering

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Measure estimation methodology applied by ANP to the measurements of a faulty sensor.

Fiscalmetering

• The longer the fault takes to be detected, the higher the probabilities ofroyalties costs being overestimated!

• Moreover, there are other economic impacts of faults for the company, suchas fines.

• This justifies the development of a system for process monitoring of fiscalmeters, as presented in this work.

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

ThesystemAMP,asystemforprocess monitoring

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

AMP:PredictiveMaintenance Application

• The AMP system is a web application operating on the AMP server andconsists of 5 components:

• client system,• data acquisition unit,• communication unit,• engine system,• database.

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

AMP:PredictiveMaintenance Application

• We applied Canonical Variate Analysis (CVA), a technique based on latentvariable modeling and dimensionality reduction, to model the statistics ofprocess data:

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

TheapplicationThemetering station

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Themetering station

• The metering station (EMED) is located at an onshore field of Petrobras.

• The EMED receives gas and oil from four satellite stations distributed alongthe field.

• The meters monitored are two orifice plate devices as gas meters and onecoriolis device as oil meter.

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Oil and gas metering station PFD

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Results

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Results

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

SPE values and gas fiscal temperature contribution during 8months.

Results

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

SPE values and gas fiscal temperature contribution during 1month.

Results

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Three scenarios for the calculation of the royalty-bearings. The black point is the maximum daily mean of production in each hatched period.

Conclusions

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Conclusions

• Test simulations of the AMP system on real data were able to detect an earlyfailure at a metering station days before the operation crew.

• It could also successfully identify, among hundreds of variables, the rootcause of the abnormal situation with fast response.

• Thus, we conclude that the application of AMP monitoring system can leadto large long-term economic gains.

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras

Thank you!Obrigado!

ProgramadeEngenhariaQuímica,COPPE/UFRJCENPES,Petrobras