RU2611275C2 - Automated stand for personnel training in oil field equipment operation - Google Patents

Abstract

FIELD: oil and gas industry.

SUBSTANCE: personnel training is carried out with the use of interactive equipment and operating equipment placed on the training range. Operating equipment of the training range and 3D-simulator includes a pumping unit (PU) with a control station, installation of electrical centrifugal pump (ECP) with shut-off valves and a control station, a screw pump sucker rod (SPSR) with shut-off valves and a control station, automated group metering stations (AGMS), the local automation unit (LAU), a bullit container, a centrifugal sectional pump (CSP) with an input filter and shut-off valves.

EFFECT: provision of training opportunities with the use of virtual and operating oilfield equipment.

2 dwg

Description

The invention relates to training tools for personnel of oil and gas companies and can be used for training, knowledge control on the efficient and safe management of oil and gas production processes for both students and specialists with advanced training working on standard oilfield equipment used at oil production facilities.

State of the art

A well-known interactive automated training system (RF patent No. 2477528, publication date 10.03.2013, IPC G09B 19/00) containing a group learning module, consisting of N workstations connected to each other at the input / output, where N is the number of trained specialists the output of which is connected to the input of the optimal design decision selection block connected to the first input of the design decision parameters input block, the first output of which is connected to the first input of the simulation module selection block, the outputs of which are connected to odes, respectively, of the study simulation module of the study object and the control module of the simulation model, while the output of the latter is connected to the input of the simulation model of the study object connected in output to the dynamic data base, and the output of the study simulation study module of the study object is connected to the static data base, the outputs of the above bases data are connected to the second input of the simulation module selection unit and to the first input of the operational information monitoring unit, the second input of which is connected to the second the output of the input block for the design parameters of the design decision, and the output is connected to the input of the block for the formation of design tasks and the adjustment of tasks, the outputs of which are connected respectively to the input of the group learning module and to the second input of the input block for the design parameters of the design decision, the simulation module for researching the object of study is made in the form of K blocks of typical simulation studies, where K is the number of types of research being conducted. The control module of the simulation model is made in the form of M blocks of control actions, where M is the number of control actions.

The disadvantage of the proposed method is that training is carried out only using a virtual model of equipment.

A known method of automated training of personnel of offshore oil and gas production platforms in extreme and emergency conditions (RF patent No. 2455699, published date 10.07.2012, IPC G09B 19/00), including the use of a computer system to create a flexible information space equipped with a knowledge base that provides for systematization emergency situations and their corresponding symptoms of technological process disturbances, emergency generation device, symptom generation device, evaluation device tions of knowledge and skills of the student in the training mode and the exam, the user device parameter settings knowledge assessment and teaching skills; a training logging device, a learner’s interface with an emergency generation device, with a symptom generating device and with a rating device, a knowledge base user interface, with a rating device and with a training recording device, while flexible information space is created by creating a virtual environment for which synthesize symptoms of an emergency and present to the student, and then, in order to detect the source of the emergency, provide the student with a medium Interaction with a virtual environment for moving simultaneously provides the learner with the possibility of virtual use of personal protective equipment and rescue equipment, taking into account the effects of the damaging factors of the accident on the learner’s virtual model, they record every action performed by the learner with a logging device, simulate the emergency development process and adaptively manage the learning process , evaluate the timeliness and correctness of the sequence of decision-making, pr They provide the user with the opportunity to select from the database of prepared accident scenarios and generation for the virtual environment of the place and emergency parameters at any time.

The disadvantage of the proposed method is that the training of personnel is carried out only using a virtual model of equipment.

Known simulators manufactured by AMT CJSC (http://amt-s.spb.ru/simulator.html). The simulator of well development and operation АМТ-601УКМ is intended for training and advanced training of workers and engineers in the departments of oil and gas production workshops (TsDNG) of oil producing enterprises, as well as for students specializing in the development and operation of oil and gas fields. The modular training class of the simulator combines training on hardware (prototype) simulators and a computer class, allowing training on the equipment of a large number of trainees under the supervision of one teacher (instructor). The simulator simulates and monitors in real and accelerated time: development and putting wells into operation, exploration in steady and unsteady conditions, operation in complicated conditions; reaction of equipment, tools, wells (changes in their condition) to the actions of the learner at the control panels and equipment control posts; occurrence and development of complications and emergency situations; testimony of control devices characterizing the condition of equipment, tools, wells; various conditions on the well (reservoir, fluid, well design); various types of oil production: in a fountain way, gas lift, with the help of ESP, USHGN, USHVN; work with AGZU, control stations, instrumentation.

The student’s workplace is a hardware training module that simulates a well, basic equipment, tools and instruments. Each module is controlled by a built-in industrial computer and equipped with a touch monitor, on which, against the background of the general view of the well, all the necessary technological information is displayed: parameter values, graphs, dynamograms, as well as animation of the equipment and processes in the well.

Training modules include: the Fountain Well module, the ESP module, the ShSNU module, the Gas-lift well module, the Gas well module, and the Injection well module.

Instructor's workplace: simulator software contains design tools for training tasks (training scenarios) with any geological and technological conditions of a production well and non-standard situations. The instructor has the opportunity, in addition to complications and emergencies that he has planned in advance in the scenario of the training task, to create them in the process of the student completing the training task. The possibility of suspension and subsequent continuation of the simulation of the technological process in any place, the possibility of a repetition of the situation, the conditions for working out the training task is provided.

When simulating technological processes, the monitor screen displays: numerical characteristics of the geological and technological conditions, graphs of the most important controlled technological parameters and animations that display in real time the operation of the equipment and the state of the well. The software keeps a log of the educational process for each student, generates a training protocol, makes it possible to evaluate the student’s actions according to the time schedules of technological parameters after the completion of classes, prints the schedules.

The disadvantage of this method of training on simulators-simulators is the interaction of trainees only with virtual and prototype models of equipment designed for the development and operation of wells.

As a prototype, “System and method of interactive learning” was selected, RF patent No. 2420811, IPC G09B 19/00, date publ. 02/27/2011, while the interactive learning system contains

- valid equipment layouts,

- simulators of parameters,

- a set of telemechanics,

- automated control system for the compressor shop,

- automated workplace of the enterprise dispatcher,

- automated workstations of operators, united by a high-performance data network,

- the equipment of the main and auxiliary facilities of the main gas pipeline was additionally introduced into the data transmission network,

- compressed air systems,

- emulators of automated control systems for main gas pipeline facilities - automated workstations of trainees,

- video surveillance complex,

- A teacher’s workstation equipped with hardware and software for managing technological and educational processes and an interpreter for creating scripts.

The disadvantage of this method of using the specified training equipment is that it cannot be used for training in oilfield equipment.

Disclosure of invention

The objective of the invention is to increase the degree of assimilation of the taught material, which allows to improve the quality of training in the preparation of specialists for work on oilfield equipment.

The problem is solved due to the fact that the training of personnel in the operation of oilfield equipment is carried out using an automated stand, on which staff are initially trained on the virtual equipment of a 3D simulator using a software package that includes modules of an automated process control system and describing the teacher’s actions algorithm, learner action algorithm, virtual equipment functionality algorithm, input A part of a 3D simulator, on which a mathematical model of the functionality of actually operating equipment located on the training ground is created, while the controlled virtual equipment and really operating equipment located on the training ground include a rocking machine (SC) with a control station, installation of an electric centrifugal pump (ESP) with shutoff valves and a control station, installation of a sucker rod pump (USHVN) with shutoff valves and a control station, automated group metering device tanovka (AGZU), a local automation unit, bullite capacity, sectional centrifugal pump (CNS) with an inlet filter and shutoff valves, while the discharge from the ESP, the discharge from UShVN, the discharge from the SC through a system of locking elements are hydraulically connected by a pipeline to the entrance to the AGZU, the exit from the gas condensate storage plant through a system of valves and check valves is hydraulically connected to the inlet of the bullite tank, the output from which is hydraulically connected through the valve system to the input of the central nervous system, and the output from the central nervous system is hydraulically connected to the discharge line.

Brief Description of the Drawings

In FIG. Figure 1 shows the layout of oilfield equipment on a 3D simulator and actual operating oilfield equipment located at a training ground. In FIG. 2 shows a diagram of a mathematical model through which communication is made with a control system of a real oilfield equipment at a training ground.

The implementation of the invention

Training of personnel in the operation of oilfield equipment is carried out using interactive equipment and operating equipment located at the training ground equipped with a control system (Fig. 1.) The existing training ground equipment includes a rocking machine (SK) 1 with a control station 2, installation of an electric centrifugal pump ( ENN) 3 with shutoff valves and a control station 4, installation of a sucker rod pump (USHVN) 5 with shutoff valves and a control station 6, automated load PPP metering unit (AGZU) 7, local automation unit (BMA) 8, bullite tank 9, centrifugal sectional pump (CNS) 10 with inlet filter and shutoff valves. Discharge 11 with ESP, discharge 12 with USHVN, discharge 13 with SC through a system of locking elements are hydraulically connected by a pipeline to the inlet of the automatic gas storage unit 7, the output of which through a system of valves and check valves is connected by a pipe 14 to the inlet of the bullet capacity 9. The output of the bullet capacity 9 is hydraulically through a valve system, connected to the input of the central nervous system 10. The output from the central nervous system 10 is hydraulically connected to the flow line.

The training is initially carried out on a 3D simulator, made in the form of a software product representing a combination of data and instructions for the operation of computer devices in order to obtain a specific result in the form of a description of the operation and control of oilfield equipment placed on a 3D simulator according to the diagram (Fig. 1 ), and creating a virtual environment (audiovisual display) that simulates the operation of virtual oilfield equipment in real conditions under the control of about his staff. The working environment is reproduced using a virtual image of oilfield equipment, a virtual image of trained personnel in overalls of an established pattern with personal protective equipment (PPE), such as a gas mask, gas analyzer, communications (walkie-talkie), etc., as well as reproducing real sounds made by the worker oilfield equipment and staff. In the process of training, noise effects are reproduced, for example, when the operator works in a gas mask, when he moves around the site, for example, talking on a walkie-talkie. The virtual environment includes communication facilities in the form of standard input-output means (keyboard-manipulator mouse) used in the interaction of a teacher or student with a simulated virtual object.

When learning how to work with the oilfield equipment of a virtual 3D simulator, the following actions are required to conduct staff training and subsequently obtain a training ground for working on the existing real oilfield equipment:

- carry out the formulation of the scenario, for example, "Launching the vessel into operation after repair";

- control the execution of the script. The task can be assigned to one or several trainees simultaneously (up to 28 people). The error made by each student in the process of completing the task is highlighted in a different color in the protocol displayed on the teacher’s monitor;

- adjust the executable script by providing the student with assistance from the teacher in performing the script;

- manage the scenario, for example, ask additional malfunctions, change the parameters of the equipment and the formation, etc .;

- retain the starting point of the new scenario for subsequent training;

- set the conditions that are not described in the given (standard) scenarios (free script).

The amount of data processed by the software product for the operation of the 3D simulator equipment (Fig. 1) includes the following production units with a list of operations performed:

1. Maintenance of the equipment of the wellhead with the list of operations in accordance with the current “Operating Instructions for wellhead fittings of the producing wells”;

2. Maintenance of wells equipped with a pumping unit 1 UShGN with a control station 2, according to the "Regulations for the operation of underground equipment of sucker rod pump installations", "Operating instructions for pumping units";

3. Maintenance of wells equipped with ESP 3 with a control station 4, according to the "Regulations for the operation of equipment of electric centrifugal pump installations";

4. Maintenance of wells equipped with UShVN 5 with a control station 6, according to the "Regulations for the operation of underground equipment of sucker-rod pump installations";

5. Maintenance of AGZU 7 according to the “Operating Instructions for automated group metering units of the“ Sputnik ”type;

6. Maintenance of injection wells;

7. Service vessels UGZU and bullite capacity 9 according to the "Instructions for the operation of vessels operating under pressure";

8. Maintenance and repair of process pipelines in accordance with the "Standard Instructions for the maintenance and repair of process pipelines";

9. Site maintenance of the central unit of the central nervous system 10 according to the “Instructions for the operation, maintenance and repair of central-type pumps of the system for the preparation and transfer of oil and water”.

On real oilfield equipment of the training ground (Fig. 1), production units are additionally implemented with a list of the following operations:

1. Well dewaxing in accordance with the “Technological regulations for mechanical dewaxing of wells with UDS, PADU, MDS installations, Instructions for the technical operation and maintenance of PADU-3, PADU-ZM, UDS-1, UDS semi-automatic dewaxing installations -1M, ADU. "

2. The supply of reagent to the well through the reagent supply unit according to the "Technological regulations for the use of equipment for the dosed supply of chemical reagent".

The training complex for working with oilfield equipment equipped with 28 personal computers includes a software package based on the control system module, with which they reproduce the interface from the real automatic process control system “Telescope +”, and also includes a communication module with elements of the training ground for oilfield equipment, teacher module and student module.

The automatic process control module included in the software package includes a mathematical model (Fig. 2), which is a computer program that implements a system of mathematical relationships that describe simulated objects and processes, multi-user access to a 3D simulator, the ability to integrate 3D- a simulator with a control system for real oilfield equipment located at the training ground, as well as storage and provision of saved scenarios.

Using the connection of the automatic process control module with the control system of the elements of the training ground for oilfield equipment, they provide the transfer of design parameters and equipment status from the mathematical model to the controller located on the site of the training ground for oilfield equipment. To implement distributed simulation using a local area network. High-level interaction between the simulator modules is implemented using IEEE 1516 (general purpose architecture for distributed computer simulation systems) standards and the OPC (OLE for Process Control) interface.

Using the teacher’s module, the previously described scenarios of working with equipment are launched both in the training mode (with tips at each step) and in the exam mode (with an assessment of the correctness of the student’s actions). The functionality of the teacher module also includes:

- the ability to display predefined faults in the 3D simulator;

- the ability to save the starting point of the script for subsequent training;

- the ability to change the operating parameters of the downhole pumping equipment and reservoir conditions;

- the ability to remotely test the student’s knowledge without the intervention of a teacher;

- the ability to intercept control of any workplace of the student.

Training of personnel in the operation of oilfield equipment at a training ground is carried out as follows:

a) using the programmed means of automation when teaching personnel how to work at a well equipped with a sucker rod pump with a deep pump (DRM) driven by a rocking machine 1 with shutoff valves and a control station 2 rocking machines, the trainees produce:

- start of the rocking machine 1, stop of the rocking machine 1 - pressure testing of the well equipped with UShGN;

- output to the well mode through the control station (SU) 2;

- installation, dismantling, connection of technical pressure gauges (instrumentation) at the well;

- change the stroke length of the rod of the deep pump;

b) using the programmed means of automation when training personnel to work on a well equipped with an electric centrifugal pump (ESP) 3 with shut-off valves and a control station 4, the trainees produce:

- commissioning of the ESP;

- removal of control parameters of the ESP;

- pressure testing of the well equipped with ESP;

- regulation of fluid withdrawal by changing the frequency - output to mode;

- underload overload;

- removal of gas plugs at the ESP;

c) using the programmed means of automation when learning how to work on a well equipped with a rod pump pump (УШВН) 5 with shut-off valves and a control station 6, the trainees produce:

- launching the USVN;

- stop;

- removal of control parameters of the UShVN;

- pressure testing of UShVN;

- regulation of fluid selection due to changes in frequency;

- output to mode;

d) using the programmed means of automation when learning how to work on an automated group metering unit (AGZU) 7, including a small automation unit 8, shutoff valves, metering devices, trainees produce:

- launch to work;

- setting and transfer of the well for measurement, control measurement;

- revision of the main nodes;

- installation and connection of technical pressure gauges;

e) using the programmed means of automation when learning how to work with the equipment of the fields, they produce:

- launch of the vessel 9 into operation;

- the conclusion of the vessel 9 from the process;

- launch of a centrifugal sectional pump (CNS) 10 with an inlet filter and shutoff valves;

- stop the central nervous system 10;

f) using the programmed means of automation when training personnel to work with the equipment of the fields, the following situations related to equipment malfunctions are also implemented: jamming of the valve; breakage of the control valve; falling wedge gate valve; a malfunction of the technical pressure gauge of the UETsN 3, UShGN 1, UShVN 5 unit, capacity 9, gas control unit 7, central nervous system 10; breakdown of the steps of the stairs of the platform for servicing the control station 2 of the rocking machine 1, tank 9, lubricator pad of the ESP 3; leakage of the annular valve UETsN 3, UShGN 1, UShVN 5; breakage of rods USHGN 1 and USHVN 5; damage to grounding ESP 3, USHGN 1, USHVN 5; sparking in the terminal box of control station 6 UShVN5, control station 2 UShGN 1, central motor 10; slipping of the drive belts of the rocking machine 1; malfunction of the spring of the reset spring safety valve (SPPK) of capacity 9, vessel AGZU 7; red silica gel transformer control station 4 ESP 3.

The operation of valves on the discharge lines 11,12, 13 and flow lines with the central nervous system 10 is simulated by means of automation, presented in the form of programmable logic controllers, in particular, by means of a potentiometer installed in the valve, which, depending on the position of the valve, gives a signal to the measuring transducer of the potentiometer position, forming a normalized analog signal in the range of 4-20 mA. The generated signal is sent to the SCADAPack controller's analog input signal model and converted to a digital 15-bit signal. Next, the received digital signal is converted in the controller into the physical value SCADAPack. This process is ongoing. After converting the signal to physical value, it is continuously polled by the I / O server, which continuously monitors the process, polls the automation system, and transfers data to the upper level. The survey is conducted using the Modbus protocol. Through the I / O server, the physical value is transferred to the mathematical model using the OPC data transfer protocol, after which the percentage of the valve's opening is displayed in the mathematical model.

For example, the production unit for vessels operating under pressure includes in the database for processing a software product the following list of operations that a student must perform on a 3D simulator and on the operating equipment of a training ground:

When performing these operations on a 3D simulator, an operation is prescribed on the monitor screen, for example, “Perform an external inspection of the vessel, pipelines, valves and all flange connections”, and at the same time, in the equipment image, in bright color, for example red, indicates which items of equipment should be checked (or with what equipment to perform the action indicated on the screen). A protocol with a list of operations and the percentage of completion of tasks is displayed on the teacher’s monitor in real time, after which the teacher assesses the level of knowledge of the student in performing this operation (for example, when starting a vessel to work after repair).

The proposed method of automated training for personnel in the operation of oilfield equipment using virtual equipment of a 3D simulator and actually operating equipment located at the training ground is effectively used at the State Budgetary Educational Institution of Secondary Professional Education “Regional Polytechnic College” of the city of Chernushka in the Perm Territory when training personnel for work with oilfield equipment of oil and gas production workshops of LUKOIL-PERM LLC.

Claims (1)

An automated stand for training personnel in the operation of oilfield equipment, which initially provides training for personnel on the virtual equipment of a 3D simulator using a software package that includes modules of an automated process control system and that describe the teacher’s actions algorithm, learner’s actions algorithm, virtual equipment functionality algorithm, which is part of the 3D simulator, on which the functional model is created the real operating equipment located at the training ground, characterized in that the controlled virtual equipment of the 3D simulator and the real operating equipment located at the training ground include a rocking machine (SC) with a control station, installation of an electric centrifugal pump (ESP) with shutoff valves and control station, installation of a rod screw pump (USHVN) with shutoff valves and control station, automated group metering unit (AGZU), local automatic machine unit iki, bullitic tank, sectional centrifugal pump (CNS) with an inlet filter and shutoff valves, with the discharge from the ESP, the discharge from USHVN, the discharge from the SC through a system of shut-off elements, are hydraulically connected by a pipeline to the entrance to the gas condensate storage plant, the exit from the gas condensate storage plant through a valve system and check valves are hydraulically connected to the inlet of the bullite tank, the output from which is hydraulically connected through the valve system to the central nervous system inlet, and the output from the central nervous system is hydraulically connected to the discharge line.

Images