petroamazonas: multi-facility visualization upgrade with virtual servers and real benefits

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Petroamazonas EP MULTI-FACILITY VISUALIZATION UPGRADE WITHVIRTUAL SERVERS AND REAL BENEFITS

Javier Maldonado – Technical Application Supervisor

Geovanny Jácome – Production Applications Coordinator (E)

Hennrry Calderón – Infrastructure Specialist

MULTI-FACILITY VISUALIZATION UPGRADE WITH VIRTUAL

SERVERS AND REAL BENEFITS

Overall benefits

Solution Selection Criteria and/or System Evolution

Business and Technical Challenge

Company Overview

AGENDA



Business Portfolio

Our operations are located in the Amazon Region and the main headquarters

offices in Quito (Ecuador´s capital city)

Main activities are Oil Exploration, Development and Production

Petroamazonas was legally named as a public company in April of 2010

In the past four years Petroamazonas received 3 new operation areas (or blocks):

B7, B21 & B18 and is developing the Block 31 (ITT) during this year.

Last year Petroamazonas merge with Petroecuador EP, and now it is the main

upstream company in Ecuador.

Contribute around the 65% of the entire oil national production

Daily average oil production 359.000 BOPD

COMPANY OVERVIEW



COMPANY OVERVIEW



EPF (46K BOPD)

B12 (EPF – PCC – DMB) & B31 (APK)



CPF (35KBOPD)

B15 – CPF - Indillana Field



Overall benefits



Company Overview

AGENDA



Background and issues

In May 2006, Blocks 12 (EPF) & 15 (CPF) operation was transferred to Ecuadorian Government from a private company

RSView®32 infrastructure was transferred to IT and Automation teams as black-boxes; which was a potential risk for the operation of both Fields (CPF & EPF)

All the base PLCs installed in the field were Allen-Bradley such as ControlLogix®, CompactLogix™ and PLC-5®.

At that time we knew the following issues: Physical servers out of warranty (obsoletes)

Operative systems (Win 2000) out of support

Missing licenses and/or duplicate serial keys

RSView32 platform not stable

Final users reporting issues on their daily basis

Potential black out or manual operation of the plant

BUSINESS AND TECHNICAL CHALLENGE



Petroamazonas made the decision to continue with Rockwell Automation

products and solutions based on:

Standardization process, including new projects in other blocks Less impact to the operation of both fields (CPF & EPF) New tools for data management trending and Data/HMI/OPC servers Certified HMI platform with Petroamazonas current hardware (HP,

Cisco, Microsoft, McAfee, EMC, Citrix, etc.) Fulfill IT and Automation users requirements Rockwell Automation Support (Service Order signed directly with

Rockwell Automation Ecuador) Rockwell Automation offered a license swap for the majority of

RSView32 and control software licenses




Project plan and phases executed:

2008: Initial meetings with Rockwell Automation team, evaluation of the product and

architecture design startup (based on physical servers)

Approval obtained to execute this migration project

2009:

Project execution (January to December) according to project plan

2010:

Both systems were moved to production (CPF & EPF)

Instant benefits were shown related whit administration processes, control, and

redundancy




2011: Continued with a stabilization phase and adjustment in both platforms

Operations started to increase in CPF and EPF

- New facilities incorporated to the main process plant

- Increased number of tags, alarms, trends, servers and licenses.

- We started having IT Infrastructure problems with our HMI servers

- The number of tags configured on the server didn’t support the minimal requirements recommended by Rockwell and we were forced to install new servers

- We increased data servers (physical servers) considerably and we were running out of space in Data Centers




Business Challenge

Keep production levels and optimize company resources

Increase availability, reliability and maintainability of monitoring and control system SCADA to avoid downtimes and improve the operation of both plants and well islands.

Provide an stable system platform for monitoring production process on both fields.

Provide real-time and historical information to end-users responsible to make operative decisions on both fields.

Provide a robust, manageable and secure HMI application supported by an stable networking, hardware and software infrastructure.






Technical Challenge

Support the business operations requirements with the latest technology available in the market

Design a new system arquitechture based on virtualization and

compatibility with supported OS Prepare, configure, test and deploy the new HMI architecture

Reduce risk and impact to the operations during the upgrade

Reduce deployment times and administration issues

Reduce and optimize IT resources




Overall benefits



Company Overview

AGENDA



Solution Criteria

Based on the business and technical challenges Petroamazonas decided to upgrade to a virtual platform – VMWare based on: Rockwell Automation applications are compatible with virtual servers

Migration and upgrade process will have less impact to the operations

IT Infrastructure optimization with virtual servers

Reduce servers configuration times using preconfigured servers templates

Better backup and data protection

Increase application availability

Better ability to respond to changing

business needs.

SOLUTION SELECTION CRITERIA



Activities executed:

2012 We continued adding new HMI data servers while we started planning the

virtualization project

Our IT Infrastructure area prepared the virtualized architecture

- Cloning the physical servers to virtual ones

- Preparing new server templates

- Storage sizing

- Validating redundancy

Migrated both HMI platforms form physical to virtual servers running on v5

2013

Based on the excellent results on virtualization, IT decided to analyze new HMI

distribute platforms in other fields, which are now implemented under the same

virtualized architecture and standards.

SYSTEM EVOLUTION



2014 Petroamazonas decided to upgrade our HMI platform to v7 CPR9 SR6

- This upgrade was a major challenge because we need to install a

complete new platform running under Win 2008 servers 64bits

instead of Windows 2003 server.

- We started the implementation with B12 - EPF

- Prepared 17 virtual servers in less than a week

- Ran both HMI platforms v5 and v7 at the same time during the

testing phase

- Implementation project executed in less than 3 months

compared to one year when we upgraded from RSView 32 to

FactoryTalk® with physical servers.

- Two other facilities (B15 & B31) are going to be upgraded in the

next weeks applying the same architecture and experiences.

SYSTEM EVOLUTION



Original Architecture - 2009

SYSTEM EVOLUTION



Final Architecture - 2011

SYSTEM EVOLUTION



Final Architecture - 2012

SYSTEM EVOLUTION



Virtualization optimization

SYSTEM EVOLUTION

Field/Block 2012 2013 - Physical servers

B15 7 physical Servers 3 Physical Server running

13 virtual servers

B12 8 physical Server 3 Physical Server running

16 virtual servers

3 Physical Server running

13 virtual servers



Virtualization optimization

SYSTEM EVOLUTION



Overall benefits



Company Overview

AGENDA



Overall IT Benefits

Less downtime issues in both plants directly related with HMI application and

processes

VMWare benefits:

faster delivery of application servers (~ 10-15 minutes per server vs 30-45 days for a

physical box),

high-availability of the servers (99.8%),

0 downtime issues during servers maintenance activities (V-Motion)

Reduction of CAPEX in servers purchase orders (~70%) physical boxes vs

VMWare

100% compliant platform with PAM EP standards: Cisco, Microsoft, VMWare,

McAfee, EMC

Storage optimization using FactoryTalk Historian versus SQL database ~ 100

GB with Historian vs 500 GB with SQL for the same database (relation 1 to 5)

OVERALL BENEFITS



Overall IT Benefits (contd..)

Rockwell Automation Architecture ensures a scalable, flexible and reliable solution

for new production facilities in other Blocks.

Increased application availability

Business continuity preparedness

End user satisfaction

Easy infrastructure management

Decrease in hardware costs

Power, cooling and space costs

Data Security

Easy of new software and hardware testing and implementation

OVERALL BENEFITS



Next Steps

Next Steps

New HMI applications for other PAM EP Fields are being designed using CPF/EPF architecture as a base, including Rockwell Automation recommendations and best practices, (Virtualization)

Improvements to networking and domain architectures according to Rockwell Automation recommendations

FactoryTalk® AssetCentre Calibration Management PlantPAx® for new projects Block 7


We care what you think!

On the mobile app:

1. Locate session using

Schedule or Agenda Builder

2. Click on the thumbs up icon on

the lower right corner of the

session detail

3. Complete survey

4. Click the Submit Form button

Please take a couple minutes to complete a quick session survey to tell us how we’re doing.

2

3

4

1

Thank you!!


PUBLIC INFORMATION

Thank you for participating!

Please remember to tidy up your work area for the next session.

We want your feedback! Please complete the session survey!

petroamazonas: multi-facility visualization upgrade with virtual servers and real benefits

Technology