Korolev Large Scale Pilot Project – Water Injection Pump Systems

In 2019 PES was employed by Schlumberger to design two systems for the automatic and safety control of eight Water Injection Pumps at the Korolev Oilfield which is located in Republic of Kazakhstan and owned by Tengizchevroil (TCO).  The aim of the control system was to improve the Reservoir Injectability and the Produced water quality.

The two control systems were split into the following operations:

A dual redundant Rockwell Control Logix PLC was programmed using the most up to date Rockwell 5000 Logix Studio software in order to ensure reliability and availability of the process. An Ethernet Device Level Ring (DLR) configuration introduced within the system allowed the PLC CPUs to communicate via Dual Redundant Ethernet Communication Modules to Remote I/O racks, to Local HMI and to a Remote HMI station.

Two Industrial Allen Bradley PCs installed with the latest version of Factory Talk View ME Studio were configured for monitoring, alarm and control purposes. A historical logging facility in the HMI PC allows the engineers onsite to view historical information such trends and past events. This  enables the client to improve the performance of the Pumps onsite as well as coordinating  maintenance activities.

Dual redundant HIMA Safety Hi Quad controllers were introduced in order to ensure safe operation and automatic protection of the Pump system. The HIMA controllers were configured to exchange data with the Process Rockwell PLC via Modbus TCP/IP protocol through Prosoft MV156E-MNETC communication modules. The data from the safety controllers is gathered via the Process Rockwell PLC and then distributed to the HMI and the Site Wide SCADA system.

A Bently Nevada 3500 Vibration and Temperature Condition Monitoring System (CMS) was introduced and configured to ensure that the Pumps and their Drive Motors were protected from potential damage. The Bently Nevada system was fitted with dual redundant Ethernet Communication modules and was configured to exchange data via Modbus TCP/IP protocol through dedicated Prosoft MV156E-MNETC communication modules with Process control Rockwell PLC. The data from the condition monitoring system was then distributed to the HMI PC and the site wide SCADA system for diagnostic, monitoring and alarm purposes.

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