Anteproyecto Vanessa Pasantia Confipetrol SAS PDF

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Francisco de Paula Santander University

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RELIABILITY TECHNIQUES TO OPTIMIZE THE OPERATION OF THE BOXES OF CONTROL SYSTEMS OF ARTIFICIAL LIFTING PCP and BES

VANESSA GONZALEZ ARENAS

Francisco de Paula Santander University ENGINEERING SCHOOL OF ELECTRONIC ENGINEERING SAN JOSE CÚCUTA 2015

Francisco de Paula Santander University

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RELIABILITY TECHNIQUES TO OPTIMIZE THE OPERATION OF THE BOXES OF CONTROL SYSTEMS OF ARTIFICIAL LIFTING PCP and BES

VANESSA GONZALEZ ARENAS COD. 1160453

DRAFT GRADE MODE "INTERNSHIP" to opt for Degree in electrical engineering

DIRECTOR ORIANA ALEXANDRA LOPEZ BUSTAMANTE ELECTRONIC ENGINEER

CO-DIRECTOR CESAR ORTIZ MAURICIO MECHANICAL ENGINEER

Francisco de Paula Santander University FACULTY OF ENGINEERING ELECTRONIC ENGINEERING SAN JOSE CÚCUTA 2015

Francisco de Paula Santander University

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TABLE OF CONTENTS P. one onePROBLEM PROBLEMSTATEMENT STATEMENT............................................... ............................................................... ................77 two twoJUSTIFICATION JUSTIFICATION................................................. ............................................................................................... ..............................................99

33PROJECT PROJECTTYPE TYPEAND ANDSCOPE SCOPE............................................. ............................................................. ................10 10 3.1 3.1PROJECT PROJECTTYPE TYPE............................................... .............................................................................. ...............................10 10 3.23.2 ALCANCES ALCANCES ................................................. ................................................. .............................................. .............................................. 10 10 4 4LIMITATIONS LIMITATIONSAND ANDLIMITATIONS LIMITATIONS............................................... ............................................... ............. ............. eleven eleven 4.1 4.1 LIMITATIONS LIMITATIONS ................................................. ......................................................................................... ........................................eleven eleven 4.2 4.2 DELIMITATIONS DELIMITATIONS ................................................. ................................................. ................................... ................................... eleven eleven 4.2.1 Space or place ............................................... .................................. eleven 4.2.2 4.2.2Weather Weather................................................. ............................................................................................... ..............................................eleven eleven

4.2.3 Objects ................................................. .............................................. eleven

55OBJECTIVES OBJECTIVES................................................. ................................................................................................... ................................................... 12 . 12

5.15.1 Overall Overall objective objective ................................................ ................................................ ....................................... ....................................... 1212

5.2 5.2Specific Specificobjectives. objectives................................................... ............................................................................... .............................12 12 6 MARCO 6 MARCO REFERENCIAL REFERENCIAL ................................................ ................................................ ................................ ................................ 1313 6.1 6.1BACKGROUND BACKGROUNDAND ANDSTATE STATEOF OFTHE THEART ART............................................. .................................................13 13 6.2 6.2THEORETICAL THEORETICALFRAMEWORK FRAMEWORK................................................ ................................................................................... ...................................14 14

6.2.1 Control boxes for artificial systems [9] uprising. ........... 14 6.2.2 6.2.2 BES BES system system (Electro (Electro Submersible Submersible Pump) Pump) ...................................... ...................................... 15 15 6.2.3 6.2.3 System System PCP PCP (Progressing (Progressing Cavity Cavity Motor) Motor) .................................... .................................... 16 16 6.2.4 6.2.4Confipetrol ConfipetrolSAS SAS................................................ ................................................................................ ................................18 18 6.36.3 LEGAL LEGAL FRAMEWORK FRAMEWORK ................................................ ................................................ ........................................ ........................................ twenty twenty

6.3.1 6.3.1 Standard Standard PAS PAS 55 55 (Asset (Asset Management) Management) .......................................... .......................................... ......... ......... twenty twenty

6.3.2

ISO 14224 (Reliability) ............................................. ..................... twenty-one

6.3.3

ISO 13379-2 (Prophetic) ........................................... ......................... twenty-one

6.3.4

ISO 13380 (Prophetic) ............................................. .......................... twenty-one

6.3.5 6.3.5 ASTM ASTM D2272-(Prophetic) D2272-(Prophetic) ............................................ ............................................ ...................... ...................... twenty-one twenty-one

6.3.6 6.3.6NTC-2050 NTC-2050(electric (electricProphetic) Prophetic)........................................... ......................................................... ..............twenty-one twenty-one

77 METHODOLOGICAL METHODOLOGICAL DESIGN DESIGN ................................................ ................................................ ........................... ........................... 22 22

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7.1 IDENTIFY TECHNOLOGIES USED IN ARTIFICIAL LIFT SYSTEMS AND BES PCP. .................................................. .. 22 7.1.1 7.1.1Activities Activities................................................. ......................................................................................... ........................................2222 7.1.2 7.1.2 Methodology................................................. Methodology................................................. ....................................... ....................................... 22 22

7.2 7.2DEFINING DEFININGTHE THEBAD BADACTORS ACTORSBOXES BOXESAND ANDCONTROL CONTROLOF OFPCP PCPBES BESSYSTEMS SYSTEMSBASED BASEDON ON RELIABILITY INDICATORS. .................................................. ............................................. 22 7.2.1 7.2.1Activities Activities................................................. ......................................................................................... ........................................2222 7.2.2 7.2.2Methodology................................................. Methodology........................................................................................ .......................................2.2.3 3

7.3 7.3SUPPORT SUPPORTTRACKING TRACKINGININFIELD FIELDOF OFBAD BADACTORS ACTORSWITH WITHSPECIALIZED SPECIALIZEDSUPPORT SUPPORT EQUIPMENT PREDICTIVE. ..................... 2. 3 7.3.1 7.3.1Activities Activities................................................. ......................................................................................... ........................................2.2.3 3 7.3.2 7.3.2Methodology................................................. Methodology........................................................................................ .......................................2.2.3 3

7.4 7.4METHOD METHODAPPLYING APPLYINGTHE THECOST-BENEFIT COST-BENEFITTHE THECORRECTIVE CORRECTIVEACTIONS ACTIONSPROPOSED PROPOSEDTO, TO,TO TO IMPROVE THE RELIABILITY OF CONTROL BOXES. .................................................. ............................. 24 7.4.1 7.4.1Activities Activities................................................. ......................................................................................... ........................................2424 7.4.2 7.4.2 Methodology................................................. Methodology................................................. ....................................... ....................................... 24 24

7.5 7.5ASKING ASKINGFOR FORIMPROVEMENT IMPROVEMENTPLANS PLANSUNDER UNDERCONTROL CONTROLBOXES BOXESreliability reliabilityanalysis. analysis. .................................................. 25 7.5.1 7.5.1Activities Activities................................................. ......................................................................................... ........................................2525 7.5.2 7.5.2 Methodology................................................. Methodology................................................. ....................................... ....................................... 25 25

8 8SCHEDULE SCHEDULE................................................. ............................................................................................. ............................................2626 9 9BUDGET BUDGET................................................. ............................................................................................. ............................................2727 1010 BIBLIOGRAPHY BIBLIOGRAPHY ................................................. ................................................. ............................................. ............................................. 2929

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LIST OF FIGURES P. Figure 1. Safety control system BES field Tibú Ecopetrol ............. 14 Figure 2. Diagram of a frequency. ................................................. fifteen Figure 3. Parts of artificial lift system BES. ................................ 16 Figure 4. Parts of PCP artificial lift system. ................................ 17 Figure 5. Processes and threads reliability. .............................................. 18 Figure 6. Process bad actors management. .................................................. ....... twenty

Francisco de Paula Santander University

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LIST OF TABLES

P. Table 1 Activity schedule ............................................. .................................. 26 Table 2 overall project budget (in thousands $). .............................................. 27 Table 3 Description personnel costs ($ thousands). ............................................... 27 Table 4 Description of equipment for own use (in thousands of $). ............................... 27 Table 5 Description of the software is planned to handle (in thousands $). .................... 28 Table 6 Description of materials and inputs (in thousands of $). ................................. 28

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Francisco de Paula Santander University

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1 PROBLEM

At present maintenance management has undergone changes in its approach, ceasing to be an activity or cyclic reconditioning equipment replacement due to economic impacts associated with unplanned shutdowns and / or cost overruns by execution or unavailability of productive assets. Engineering Maintenance and Reliability (IMC) is to increase productivity, analyze the probability of failure, capacity systems and equipment, maintainability, availability, safety and quality standards, becoming a strategic opportunity factor necessary to achieve the objectives in corporate business units in a globalized world and today's competitive.

BMI is a vitally important process in oil, mining, among others, consisting of processes and threads based on reliability techniques with seeking maximum business profitability and manage an integrated management model of productive assets. One of its main processes is reliability, which in turn is divided into 6 sub-processes: Root Cause Analysis ( Root cause analysis, RCA), Bad Actors, Reliability Measurement Indicators ( Reliability measurement indicators, RIM), Cost Analysis Life Cycle (LCCA), Reliability Centered Maintenance ( Reliability Centered Maintenance, RCM) and improvement plans, which complement each other to optimize the function of the equipment [1].

Artificial lift systems used in the oil industry are studied to improve efficiency. These are composed of sets of key equipment in the production process, including control boxes of the two most used systems are: Progressing Cavity Engines ( Progressing Cavity Pump, PCP) and Electro Submersible Pumps ( Electro Submersible Pump, BES). These systems that drive the oil and natural gas to the surface, have different control devices because of their varying load. These have a high willingness to fail due to the harsh working conditions to which they are exposed, it is for them it is necessary to work on improvement plans to optimize its operational performance.

Ecopetrol SA is the country's largest company and the leading oil company in Colombia. For its size, Ecopetrol SA belongs to the group of the 39 largest oil companies in the world and is one of the five largest in Latin America. Thanks to their strengths and competencies, Ecopetrol SA is a leader in Colombia and preferred partner to explore and produce hydrocarbons. Concern is the protection of life and the environment, for this reason, wants its employees and contractors are

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committed to best practices, applying international standards and following guidelines established by professional staff [2]. Confipetrol SAS, allied contractor Ecopetrol SA specializes in providing comprehensive operation and maintenance focused on reliability engineering and predictive diagnostic techniques aimed at industrial and energy sectors, gas, petrochemical, formed by a highly qualified team company and organization committed to customer satisfaction. This company is responsible for implementing engineering maintenance and reliability in different managements of Ecopetrol SA and other customers, ensuring proper use innovation and technology [3].

The project aims to implement specific engineering expertise in electronic control and reliability techniques to optimize the operation of the control boxes of PCP and BES systems, formulating improvement plans related to the functions of Confipetrol SAS with operations management and production Ecopetrol SA Catatumbo.

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Francisco de Paula Santander University

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2 RATIONALE

The implementation of electrical, electronic and control knowledge, along with reliability techniques to detect, analyze, correct cause failures and improve the efficiency of control boxes PCPs and BES systems operations management Catatumbo Ecopetrol SA, contribute to reducing accidents that threaten the integrity of its employees, supporting the flagship program of the company's "commitment to life" [4].

You have control over getting production operations with efficient operation of the structure of oil extraction and artificial gas, contributing to environmental care, avoiding possible oil spills and accidents effects caused by natural gas. the operation is regulated with a safe, healthy and pleasant system, increasing clean cities and friendly environments. Engineering techniques to ensure operability, accidents that negatively impact the natural means of production are prevented, improving the quality of deposits drilled by ensuring play an important achievement of Ecopetrol SA and Confipetrol

SAS, as is the commitment to good conduct and best application engineering in improving production [4].

It is noteworthy that the economic benefits are ensured by implementing techniques reliability control boxes, which are used in the most efficient extraction systems artificial oil, are checked by measuring the general indicators with cost-effective methods, where the monetary cost between what is invested with the strategy to be implemented, and the benefits gained by increasing production and reducing downtime due to failures in a given time is compared. Yes comparison yields positive results will be reflected in increased bpd, in summary represents increased profits for all parties involved [4].

In summary the project will extend the lifecycle of each system and improve the operation of the control boxes that are involved, obtaining corporate profits, maintaining infrastructure free of significant accidents and increasing profits to shareholders and companies linked directly or indirectly.

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Francisco de Paula Santander University

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3 LETTER PROJECT AND SCOPE

3.1 TYPE OF PROJECT

The mode project internship: reliability techniques to optimize the operation of the control boxes in artificial lift systems PCP and BES, is a descriptive-explanatory research, it seeks to specify the properties and characteristics that present systems, to eradicate the causes events, events and phenomena that cause malfunction from his command and contribute to improved performance.

3.2 ALCANCES

With the development of the project internship modality it is to improve the performance and operational efficiency of the control boxes of PCP and BES Tibu Ecopetrol SA field systems using techniques reliability as a measure of fault indicators, Root Cause Analysis, Bad actors and cost-benefit analysis. To get a sense of the historical fault there will be software Ellipse ( Computerized maintenance management systems, CMMS)

devices such as network analyzer will be used to follow the behavior of energy in the load, and finally applying the electrical, electronic and control knowledge, optimize the system in general.

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Francisco de Paula Santander University

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4 LIMITATIONS AND LIMITATIONS

The extension project has limitations and boundaries of space, time and objects as described below.

4.1 LIMITATIONS

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Control boxes with which contact management Catatumbo Ecopetrol SA will, be those belonging to the Tibu field, which work with PCP artificial lift systems and BES.

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The project is subject to work with Excel database property Confipetrol SAS software maintenance and CMMS EL...