🛢️ SCADA/DCS | SIL 3 | ATEX/IECEx | API | HIPPS

سیستم کنترل نفت و گاز

Oil & Gas Process Control System

سیستم SCADA/DCS یکپارچه برای تأسیسات بالادستی و پایین‌دستی نفت و گاز | Well Control | Separation | Compression | Metering
رقیب Honeywell Experion | Emerson DeltaV | ABB 800xA | Yokogawa CENTUM

🎯 دیاگرام فرآیند📋 ۲۰ زیرسیستم
20
Subsystem
SCADA
Pipeline
SIL 3
Safety
ATEX
Zone 1/2
API
Custody
HIPPS
SIL 3
Hart
Foundation
99.9%
Uptime
📊 Plant Overview

نمای کلی تأسیسات

Real-time SCADA Status | 125 MMSCFD Gas Processing Facility

🛢️
125
MMSCFD
↑ 2.5%
💧
8,500
BPD Oil
↑ 1.2%
💦
12,000
BPD Water
↓ 3.1%
📊
850
psig Inlet
±5
🌡️
65
°C Process
±2
⚡
94.5
% Efficiency
↑ 0.5%
🔔
3
Active Alarms
Low
✅
Normal
Status
All Safe
📐 Process Flow Diagram

دیاگرام فرآیند

125 MMSCFD Gas Processing Facility | Wellhead to Export

🛢️ Oil & Gas Processing Facility - Live PFD
✓ All Systems OnlineNormal Operation125 MMSCFD
WELLS W-01 to W-12 ESP GL RP 12 Manifold 12 Wells 850 psig Test Sep V-001 HP Sep V-101 800 psig LP Sep V-102 150 psig Heater Treater V-103 85°C TEG Dehy T-101 Compressor Station C1 C2 S 1,200 psig Metering Custody 125 Pipeline Export 24" × 50km 1,150 psig Tank Farm TK-101 TK-102 TK-103 LACT Oil Export 8,500 BPD Water Treat CPI + IGF 12,000 BPD Injection Well IW-01 Flare HP/LP
125
MMSCFD Gas
8,500
BPD Oil
12,000
BPD Water
850
psig Inlet
1,150
psig Export
94.5%
Recovery
12
Active Wells
Normal
ESD Status
🛢️ Well Control

کنترل چاه‌ها

ESP | Gas Lift | Rod Pump | Well Testing | Allocation

🛢️ Well Control System - 12 Active Wells
✓ 10 Online1 Testing1 Workover
🛢️
W-01 (ESP)
450 HP Submersible
Flow
850
BPD
Fluid
THP
320
psig
WHP
🛢️
W-02 (ESP)
350 HP Submersible
Flow
720
BPD
Fluid
THP
295
psig
WHP
💨
W-03 (GL)
Gas Lift 2 MMSCFD
Flow
580
BPD
Fluid
Inj
1.8
MMSCF
GL
💨
W-04 (GL)
Gas Lift 1.5 MMSCFD
Flow
420
BPD
Fluid
Inj
1.2
MMSCF
GL
⚙️
W-05 (RP)
Rod Pump 20 SPM
Flow
180
BPD
Fluid
SPM
18
Stroke
Rate
🔧
W-06 (Test)
Well Testing
Status
Testing
Time
4h
GOR
2,500
scf/bbl
Test
/* Well Production Equations */ IPR: q = J × (Pr - Pwf) // Productivity Index Vogel: q/qmax = 1 - 0.2(Pwf/Pr) - 0.8(Pwf/Pr)² ESP: TDH = Pd - Ps + Friction + ΔZ Gas Lift: GLR_opt = f(depth, PI, GOR)
ESP Frequency Control
AUTO
Freq
55 Hz
Amps
85 A
Intake P
450 psi
Motor T
185°F
🛡️ Well Protection
⚠️ ESP Underload < 40% (Gas Lock)
⚠️ ESP Overload > 110%
⚠️ Motor Temp High > 300°F
⚠️ Intake Pressure Low < 200 psi
⚠️ High Vibration > 0.5 in/s
⚠️ SCSSV Closure on ESD
🔵 Separation

جداسازی نفت و گاز

2-Phase | 3-Phase | Test Separator | Level/Pressure Control

🔵 Separation System
✓ NormalHP/LP ActiveV-101/102
🔵
V-101 HP Separator
3-Phase 800 psig
Pressure
800
psig
HP
Level
45%
Oil
Level
🔵
V-102 LP Separator
3-Phase 150 psig
Pressure
150
psig
LP
Level
52%
Oil
Level
🟡
V-001 Test Separator
Well Test 24h
Well
W-06
Test
Active
GOR
2,500
scf/bbl
Calc
🔴
V-103 Heater Treater
BS&W < 0.5%
Temp
85
°C
Process
BS&W
0.3%
Oil
Quality
HP Sep Level Control (LIC-101)
CASCADE
PV
45%
SP
50%
OP
42%
LCV
Open
HP Sep Pressure Control (PIC-101)
AUTO
PV
800 psi
SP
800 psi
OP
55%
PCV
Open
🛡️ Separator Protection
⚠️ LAHH Level > 80% → Close Inlet SDV
⚠️ LALL Level < 10% → Close Outlet LCV
⚠️ PAHH Pressure > 850 psi → PSV/BDV
⚠️ PALL Pressure < 50 psi → Alarm
⚠️ TAHH Temp > 90°C → Trip Heater
🔮 Compression

ایستگاه تقویت فشار

Reciprocating | Centrifugal | Anti-Surge | Load Sharing

🔮 Compressor Station
✓ 2 RunningLoad Sharing1,200 psig
🔮
C-101 Centrifugal
2-Stage 8,000 HP
Speed
9,850
RPM
Shaft
Load
78%
Power
6,240 HP
🔮
C-102 Centrifugal
2-Stage 8,000 HP
Speed
9,720
RPM
Shaft
Load
75%
Power
6,000 HP
🔮
C-103 Standby
2-Stage 8,000 HP
Status
Standby
Mode
Auto Start
Health
OK
Ready
Yes
🛡️
Anti-Surge System
CCC Anti-Surge
Margin
18%
to Surge
Safe
ASV
0%
Recycle
Closed
/* Compressor Performance */ Head = (Z×R×T/MW)×[(Pd/Ps)^((k-1)/k) - 1] Surge Line: H = f(Q) at constant speed Anti-Surge: UIC opens ASV before surge Load Sharing: Equal distance to surge
Discharge Pressure (PIC-201)
CASCADE
PV
1,200 psi
SP
1,200 psi
Speed
9,850
Mode
Load
🛡️ Compressor Protection
⚠️ Surge Detected → Open ASV 100%
⚠️ High Vibration > 1.0 in/s → Trip
⚠️ High Discharge Temp > 350°F
⚠️ Low Suction Pressure < 100 psi
⚠️ Low Lube Oil Pressure < 15 psi
⚠️ High Thrust Bearing Temp > 250°F
🛢️ Tank Farm

مخازن ذخیره

Floating Roof | Fixed Roof | Level | Temperature | Inventory

🛢️ Tank Farm - Oil Storage
✓ 4 Tanks80,000 BBL TotalATG Active
🛢️
TK-101 Crude
Floating Roof 20,000 BBL
Level
78%
15,600 BBL
Volume
Temp
42°C
API 32
Gravity
🛢️
TK-102 Crude
Floating Roof 20,000 BBL
Level
45%
9,000 BBL
Volume
Temp
40°C
API 32
Gravity
🛢️
TK-103 Export
Fixed Roof 20,000 BBL
Level
92%
18,400 BBL
Volume
Temp
38°C
API 33
Gravity
🛢️
TK-104 Slop
Fixed Roof 5,000 BBL
Level
15%
750 BBL
Volume
Temp
35°C
BS&W
8%
TK-101
78%
TK-102
45%
TK-103
92%
TK-104
15%
📊 Metering

اندازه‌گیری و تحویل

Custody Transfer | LACT | Allocation | API MPMS

📊 Custody Transfer Metering - API MPMS
✓ ProvedGas + Oil±0.1% Accuracy
📊
Gas Metering
Ultrasonic 8-Path
Flow
125
MMSCFD
Rate
Total
45.2
BSCF
Accum
📊
LACT Unit
PD Meter + Prover
Flow
8,500
BPD
Rate
MF
1.0002
Factor
Meter
🔬
Gas Chromatograph
Online GC Analysis
C1
92.5%
Methane
Mol%
BTU
1,045
Heating
Value
🧪
BS&W Analyzer
Capacitance Type
BS&W
0.3%
Limit
< 0.5%
API
32.5
Gravity
°API
🔗 Pipeline

خط لوله صادراتی

SCADA | Leak Detection | Pig Tracking | Batch Management

🔗 Pipeline SCADA - 50 km Export Line
✓ Flowing125 MMSCFDNo Leak
📍
KP-0 Inlet
Launcher Station
Pressure
1,150
psig
Inlet
Flow
125
MMSCFD
Rate
📍
KP-15 Block
Block Valve Station
Pressure
1,120
psig
Mid
SDV
Open
Status
Normal
📍
KP-30 Block
Block Valve Station
Pressure
1,085
psig
Mid
SDV
Open
Status
Normal
📍
KP-50 Outlet
Receiver Station
Pressure
1,050
psig
Outlet
Flow
124.5
MMSCFD
Rate
🔍
Leak Detection
RTTM + Mass Balance
Status
No Leak
System
Active
Imbalance
0.2%
Threshold
< 1%
🛡️ ESD

سیستم خاموشی اضطراری

IEC 61511 | SIL 3 | Cause & Effect | HIPPS

🛡️ Emergency Shutdown System - SIL 3
✓ ArmedSafe StatePFDavg 5E-4
🔴
ESD Level 1
Total Plant Shutdown
Status
Safe
SIL
SIL 3
Voting
2oo3
Logic
Active
🟠
ESD Level 2
Process Unit SD
Status
Safe
SIL
SIL 2
Voting
1oo2
Logic
Active
🟡
ESD Level 3
Equipment SD
Status
Safe
SIL
SIL 2
Voting
1oo1
Logic
Active
🛡️
HIPPS
High Integrity PSS
Status
Safe
SIL
SIL 3
Voting
2oo3
PST
Pass
🛡️ ESD Cause & Effect Matrix
ESD-1: Manual Station | Confirmed Fire | Gas Release | Process PAHH
ESD-2: Process Unit PAHH/LAHH | Equipment Trip | Local Manual
ESD-3: Individual Equipment Protection | Local Interlocks
HIPPS: Pipeline PAHH > 1,250 psig | Fast Acting SDV Close < 2s
🔥 Fire & Gas

سیستم آتش و گاز

Gas Detection | Fire Detection | Deluge | VESDA | Suppression

🔥 Fire & Gas Detection System
✓ All Clear245 DetectorsSIL 2
💨
Gas Detection
Catalytic + IR
Points
85
Detectors
Active
Alarm
0
Active
Clear
🔥
Fire Detection
UV/IR + Heat
Points
120
Detectors
Active
Alarm
0
Active
Clear
💨
H2S Detection
Electrochemical
Points
25
Detectors
Active
Max
2 ppm
Reading
Safe
💧
Deluge System
Fire Water
Zones
8
Coverage
100%
Pressure
125
psig
Ready
🧯
Suppression
FM-200 / CO2
Rooms
5
Protected
Areas
Status
Armed
System
Ready
🔥 Flare

سیستم فلر

HP/LP Flare | KO Drum | Pilots | Smokeless

🔥 Flare System
✓ Pilots OKMinimal FlaringSmokeless
🔥
HP Flare
150 psig Header
Flow
0.5
MMSCFD
Rate
Pilots
3/3
Lit
OK
🔥
LP Flare
15 psig Header
Flow
0.2
MMSCFD
Rate
Pilots
2/2
Lit
OK
🛢️
HP KO Drum
V-301 Knockout
Level
5%
Empty
Normal
LAHH
OK
Interlock
Armed
💨
Smokeless
Steam/Air Assist
Steam
Auto
Mode
Active
Smoke
None
Visual
Clear
🏭 Subsystems

۲۰ زیرسیستم کنترل نفت و گاز

Comprehensive SCADA/DCS Coverage for Oil & Gas Facilities

🛢️
کنترل چاه
Well Control
ESP, Gas Lift, Rod Pump, Well Testing, Production Allocation
ESP VSDGL ValveSCSSVAllocation
Wells: 50I/O: 1,500
🔵
جداسازی
Separation System
2/3-Phase Separators, Test Separator, Level/Pressure Control
HP SepLP SepTest SepHeater
Vessels: 12I/O: 480
🔮
تقویت فشار
Compression
Reciprocating, Centrifugal, Anti-Surge, Load Sharing
RecipCentrifAnti-SurgeCCC
Units: 6I/O: 850
🛢️
مخازن
Tank Farm
ATG, Level, Temperature, Inventory, Overfill Protection
ATGOHPSInventoryTransfer
Tanks: 20I/O: 320
🔗
خط لوله
Pipeline SCADA
Leak Detection, Pig Tracking, Batch, Pressure Management
RTTMPig TrackBatchSDV
KM: 500RTU: 25
🛡️
خاموشی اضطراری
ESD System
IEC 61511, SIL 2/3, Cause & Effect, HIPPS, BDV
ESD-1/2/3HIPPSBDVC&E
SIF: 85PFD: 5E-4
🔥
آتش و گاز
Fire & Gas
Gas/Fire Detection, H2S, Deluge, Suppression, VESDA
Cat/IRUV/IRH2SDeluge
Points: 245SIL: SIL 2
🔥
سیستم فلر
Flare System
HP/LP Flare, KO Drum, Pilots, Smokeless, Recovery
HP FlareLP FlareKO DrumVRU
Headers: 2I/O: 120
📊
اندازه‌گیری
Metering & Custody
Custody Transfer, LACT, Allocation, API MPMS, Prover
USMLACTGCProver
Meters: 15Accuracy: ±0.1%
💧
تصفیه آب
Water Treatment
Produced Water, CPI, IGF, Hydrocyclone, Injection
CPIIGFFilterInject
BPD: 50KI/O: 280
🌡️
گرمایش
Heating System
Fired Heater, Heat Exchanger, Hot Oil, Glycol Regen
FiredHot OilHXBMS
Units: 8I/O: 240
💨
نم‌زدایی
Dehydration
TEG, Mol Sieve, Desiccant, Dew Point Control
TEGRegenFlashStripping
Units: 2I/O: 180
🧪
شیرین‌سازی
Gas Sweetening
Amine, H2S/CO2 Removal, Acid Gas, Sulfur Recovery
AmineRegenFlashSRU
Units: 2I/O: 320
⚡
برق و نیرو
Power Generation
Gas Turbine, Generator, Switchgear, UPS, Emergency
GTGAVRSyncUPS
MW: 50I/O: 420
🔧
یوتیلیتی
Utilities
Instrument Air, Fuel Gas, Nitrogen, Service Water
IAFGN2SW
Systems: 8I/O: 280
📡
پایش وضعیت
Condition Monitoring
Vibration, Temperature, Oil Analysis, Predictive
VibrationTSIOilPdM
Points: 450Machines: 35
🔔
مدیریت آلارم
Alarm Management
ISA 18.2, EEMUA 191, Rationalization, Analytics
ISA 18.2EEMUAKPIShelving
Tags: 8KRate: < 6/h
💾
هیستورین
Historian & Reports
PI/Historian, SOE, Reports, KPIs, Data Analytics
PISOEReportsBI
Tags: 50KYears: 10
🔐
امنیت OT
Cybersecurity
IEC 62443, Firewall, IDS/IPS, Access, Patching
IEC 62443DMZSIEMSOC
SL: SL 2Zones: 6
🖥️
HMI و اپراتور
Operator Interface
Graphics, Faceplates, Trends, Alarms, HP ASM
HP ASMISA 101MobileAR/VR
Screens: 400Stations: 12
⚠️ Hazardous Areas

مناطق خطرناک

ATEX/IECEx Classification | Zone 0/1/2

Zone 0
Continuous Hazard
Inside Vessels, Sumps, Drains
Ex ia / IS Required
Zone 1
Frequent Hazard
Wellheads, Separators, Compressors
Ex d / Ex e / Ex p
Zone 2
Infrequent Hazard
Process Areas, Tank Farm
Ex n / Ex e
🔧 Phoenix Platform

معماری سیستم Phoenix

سه لایه SCADA/RTU/I/O برای نفت و گاز

🖥️
Phoenix SCADA
Master Station / Control Center
Point Capacity
500,000+
RTU Support
1,000+
Redundancy
Hot Standby
Protocol
DNP3/Modbus/104
Historian
50,000 Tags
Communication
Satellite/Radio/Fiber
⚙️
Phoenix RTU
Remote Terminal Unit
Operating Temp
-40 to +70°C
I/O Capacity
500 per RTU
Local Logic
IEC 61131-3
Store & Forward
30 Days
Power
Solar/Battery
Enclosure
NEMA 4X / IP66
📡
Phoenix I/O
Field I/O & Instruments
HART Support
Full Pass-Through
AI Resolution
16-bit
Intrinsic Safe
Ex ia IIC
Flameproof
Ex d IIB+H2
SIL Rating
SIL 2/3
ATEX/IECEx
Certified
📈 ROI

مزایای اقتصادی

Return on Investment | Production Optimization

+15%
Production Increase
-60%
Downtime Reduction
>99%
System Uptime
-40%
Safety Incidents
<18mo
Payback Period
85%
Cost Savings vs Competitors