Loading
Rockwell Automation Home
  • Industries
    • Industries Chevron RightChevron Right
      • Automotive & Tire
      • Cement
      • Chemical
      • Entertainment
      • Fibers & Textiles
      • Food & Beverage
      • Household & Personal Care
      • Infrastructure
      • Life Sciences
      • Marine
      • Metals
      • Mining
      • Oil & Gas
      • Power Generation
      • Print & Publishing
      • Pulp & Paper
      • Semiconductor
      • Water Wastewater
      • View All
    Industries
    Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
  • Capabilities
    • Capabilities Chevron RightChevron Right
      • The Connected Enterprise®
      • Consulting & Integration Services
      • Cybersecurity
      • Digital Transformation
      • Industrial Analytics
      • Industrial Automation & Control
      • Industrial Maintenance & Support
      • Industrial Networks
      • Lifecycle Services
      • Machine & Equipment Builders
      • MES Solutions
      • Process Solutions
      • Safety Solutions
      • View All
    Capabilities
    Blogs DistributorDistributor How to Buy EventEvent Events
  • Products
    • Hardware Chevron RightChevron Right
    • Software Chevron RightChevron Right
      • Circuit & Load Protection
      • Condition Monitoring
      • Connection Devices
      • Distributed Control Systems
      • Drives & Motors
      • Energy Monitoring
      • Human Machine Interface
      • Independent Cart Technology
      • Industrial Computers & Monitors
      • Input/Output Modules
      • Industrial Control Products
      • Lighting Control
      • Motion Control
      • Motor Control
      • Networks Security & Infrastructure
      • Packaged Solutions
      • Power Supplies
      • Programmable Controllers
      • Push Buttons & Signaling Devices
      • Relays & Timers
      • Safety Instrumented Systems
      • Safety Products
      • Sensors & Switches
      • Signal Interface
      • View All Hardware Products
    • DesignSuite
      • Dynamic Digital Twin Software
      • Studio 5000 Design Software
    • OperationSuite
      • FactoryTalk Edge Gateway
      • FactoryTalk Batch
      • FactoryTalk Historian
      • FactoryTalk View - HMI Software
      • FactoryTalk Metrics
    • MaintenanceSuite
      • FactoryTalk Analytics for Devices
      • FactoryTalk AssetCentre
      • FactoryTalk Emonitor
      • FactoryTalk Network Manager
      • FactoryTalk TeamONE
      • Fiix CMMS
    • InnovationSuite
      • Augmented Reality
      • FactoryTalk Analytics
      • MES
      • ThingWorx IIoT Platform
    Products
    Find Products by Our Brands: Allen-Bradley FactoryTalk
  • Support
    • Product Support Chevron RightChevron Right
    • Documentation Chevron RightChevron Right
    • Knowledgebase Chevron RightChevron Right
    • Training Chevron RightChevron Right
    • Downloads
      • 2D & 3D Drawings
      • Activations
      • Add-on Profiles
      • Application Code Libraries
      • Compatibility & Downloads
      • Drivers & Firmware
      • Electronic Datasheets
      • EPLAN Macros
      • Sample Code Library
      • Software Patches
      • View All
    • Selection & Configuration
      • Control Systems Configuration Tools
      • Procurement Specifications
      • ProposalWorks Proposal Builder
      • Global Short-circuit Current Ratings Tool
      • Integrated Architecture Builder
      • View All
    • Compatibility & Migration
      • Migration & Modernization
      • Lifecycle Status
      • Product Replacement Lookup
      • View All
      • Technical Documentation Center
      • Technical Specifications
      • Product Certifications
      • Product Drawings
      • Release Notes
      • Literature Library
    • Support Center
      • Support Options
      • Search for Answers
      • Chat Online
      • Call Us
      • View All
    • Online Forum
      • My Inbox
      • My Favorites
      • My Subscriptions
      • View All
    • My TechConnect
      • Chat History
      • Service Ticket History
      • Manage Your Favorite Answers
      • Field Service Request
      • View All
      • E-Learning Courses
      • Instructor-led Courses
      • Training Workstations
      • View All
    Support
    Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
  • Company
    • Events Chevron RightChevron Right
    • News Chevron RightChevron Right
    • Careers Chevron RightChevron Right
    • PartnerNetwork Chevron RightChevron Right
    • About Us Chevron RightChevron Right
    • Featured Events
      • Automation Fair
      • Process Solutions User Group
      • Rockwell Automation On The Move
      • Rockwell Automation TechEd
      • ROKLive
      • India Inc. on the Move
      • PACK EXPO CONNECTS
      • Virtual Summit Chemical
      • Virtual Summit Life Science
      • Virtual Summit Warehouse
      • View All
    • Webinars
      • Live
      • On-Demand
      • View All
      • Blogs
      • Case Studies
      • Automation Today
      • Podcasts
      • Press Releases
      • View All
      • View Jobs
      • Teams & People
      • Hackathon
      • Employee Video Spotlight
      • Authorized Distributors
      • Encompass Product Partners
      • Licensed Developers
      • OEM Partners
      • Strategic Alliance Partners
      • System Integrator Partners
      • PartnerNetwork Portal
      • View All
      • Our Brands
      • Our Community
      • Our History
      • Integrity & Sustainability
      • Investor Relations
      • View All
    Company
    ProductivityProductivity Investor Relations
  • Sales
  • Sales
  • View All Industries
  • View All
  • View All
  • View All
  • View All
  • Automotive & Tire
  • Cement
  • Chemical
  • Entertainment
  • Fibers & Textiles
  • Food & Beverage
  • Household & Personal Care
  • Infrastructure
  • Life Sciences
  • Marine
  • Metals
  • Mining
  • Oil & Gas
  • Power Generation
  • Print & Publishing
  • Pulp & Paper
  • Semiconductor
  • Water Wastewater
  • View All
  • The Connected Enterprise®
  • Consulting & Integration Services
  • Cybersecurity
  • Digital Transformation
  • Industrial Analytics
  • Industrial Automation & Control
  • Industrial Maintenance & Support
  • Industrial Networks
  • Lifecycle Services
  • Machine & Equipment Builders
  • MES Solutions
  • Process Solutions
  • Safety Solutions
  • View All
  • Circuit & Load Protection
  • Condition Monitoring
  • Connection Devices
  • Distributed Control Systems
  • Drives & Motors
  • Energy Monitoring
  • Human Machine Interface
  • Industrial Computers & Monitors
  • Input/Output Modules
  • Industrial Control Products
  • Lighting Control
  • Motion Control
  • Motor Control
  • Networks Security & Infrastructure
  • Packaged Solutions
  • Power Supplies
  • Programmable Controllers
  • Push Buttons & Signaling Devices
  • Relays & Timers
  • Safety Instrumented Systems
  • Safety Products
  • Sensors & Switches
  • Signal Interface
  • View All Hardware Products
  • View All
  • View All
  • Technical Documentation Center
  • Technical Specifications
  • Product Certifications
  • Product Drawings
  • Release Notes
  • Literature Library
  • View All
  • Instructor-led Courses
  • Training Workstations
  • View All
  • View All
  • Blogs
  • Case Studies
  • Automation Today
  • Podcasts
  • Press Releases
  • View All
  • View Jobs
  • View All
  • Authorized Distributors
  • Encompass Product Partners
  • Licensed Developers
  • OEM Partners
  • System Integrator Partners
  • PartnerNetwork Portal
  • View All
  • Our Brands
  • Our History
  • Investor Relations
  • View All
  • iTRAK Intelligent Track Systems
  • MagneMover Lite Intelligent Conveyor System
  • QuickStick Intelligent Conveyor System
  • View All
  • Dynamic Digital Twin Software
  • Studio 5000 Design Software
  • FactoryTalk Edge Gateway
  • FactoryTalk Batch
  • FactoryTalk Historian
  • FactoryTalk View - HMI Software
  • FactoryTalk Metrics
  • FactoryTalk Analytics for Devices
  • FactoryTalk AssetCentre
  • FactoryTalk Emonitor
  • FactoryTalk Network Manager
  • FactoryTalk TeamONE
  • Fiix CMMS
  • Augmented Reality
  • FactoryTalk Analytics
  • MES
  • ThingWorx IIoT Platform
  • 2D & 3D Drawings
  • Activations
  • Add-on Profiles
  • Application Code Libraries
  • Compatibility & Downloads
  • Drivers & Firmware
  • Electronic Datasheets
  • EPLAN Macros
  • Sample Code Library
  • Software Patches
  • View All
  • Control Systems Configuration Tools
  • Procurement Specifications
  • ProposalWorks Proposal Builder
  • Global Short-circuit Current Ratings Tool
  • Integrated Architecture Builder
  • View All
  • Migration & Modernization
  • Lifecycle Status
  • Product Replacement Lookup
  • View All
  • Support Options
  • Search for Answers
  • Chat Online
  • Call Us
  • View All
  • My Inbox
  • My Favorites
  • My Subscriptions
  • View All
  • Chat History
  • Service Ticket History
  • Manage Your Favorite Answers
  • Field Service Request
  • View All
  • My Training
  • View All
  • Automation Fair
  • Process Solutions User Group
  • Rockwell Automation On The Move
  • Rockwell Automation TechEd
  • ROKLive
  • India Inc. on the Move
  • PACK EXPO CONNECTS
  • Virtual Summit Chemical
  • Virtual Summit Life Science
  • Virtual Summit Warehouse
  • View All
  • Live
  • On-Demand
  • View All
  • Students & New Grads
  • View All
  • Hackathon Use Case for Manufacturing Optimization
  • Hackathon Use Case for Sustainability
  • Hackathon Use Case for Visual System Modernization
  • Hackathon Use Case for Dynamic Filtering
  • View All
  • 24toCode Event Recap - Winter 2019
  • 24toCode Event Recap // IT Internal Hackathon
  • Meet the 2019 IT Summer Interns
  • 24toCode Promo Video
  • Harbor View Plaza Ribbon Cutting
  • Check Your Blind Spots Mobile Tour at Rockwell Automation
  • Mechanic & Tool Apprenticeship at Rockwell Automation
  • Working at Rockwell Automation in Karlsruhe
  • Summer Internships at Rockwell Automation
  • The Intrapreneurial Skills Accelerator at Rockwell Automation
  • Makers Wanted
  • #LifeatROK w Katowicach
  • IT Summer Internship Program
  • #LifeatROK with Diogo
  • View All
  • Cisco
  • Endress+Hauser
  • FANUC
  • Microsoft
  • Panduit
  • View All
  • Our Focused Giving
  • STEM Education
  • Lifelong Learning
  • View All
  • Sustainability Report
  • Our Commitment to Diversity, Equity and Inclusion
  • Environmental, Health, & Safety
  • Ethics & Compliance
  • Global Supply Chain & Sourcing
  • Product Environmental Compliance
  • Quality Management Systems
  • Trust & Security
  • Workforce of Tomorrow
  • View All
Case StudyRockwell Automation's case studies Case Studies DistributorDistributor How to Buy EventEvent Events
Blogs DistributorDistributor How to Buy EventEvent Events
Find Products by Our Brands:
Allen-Bradley FactoryTalk
Contact Us HelpHelp Get Support LaunchpadTools and applications View All Tools
ProductivityProductivity Investor Relations
  • Literature LibraryLiterature Library
    Literature Library

    Access technical and commercial publications for hardware and software products, applications, services and solutions.

    PCDCProduct Compatibility and Download Center
    Compatibility & Downloads

    Find downloads including firmware, release notes, associated software, drivers, tools and utilities.

    KnowledgebaseKnowledgebase Support Center
    Knowledgebase

    Browse the database of questions and answers on a variety of products and technologies.

    Product ConfiguratorProduct Configurator
    Product Configurator

    Configure and select products rapidly.

    Software SubscriptionsSoftware Subscriptions
    Software Subscriptions

    One stop shopping for software and subscription services.

    2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
    Tools
    UserUser Sign In/Create an Account
  • User Account User
Tools
Literature LibraryLiterature Library
Literature Library
PCDCProduct Compatibility and Download Center
Compatibility & Downloads
KnowledgebaseKnowledgebase Support Center
Knowledgebase
Product ConfiguratorProduct Configurator
Product Configurator
Software SubscriptionsSoftware Subscriptions
Software Subscriptions
2D & 3D Drawings Bill of Materials CrossWorks Electronic Datasheets Motion Analyzer My Equipment My Training E-Learning Portal Product Lifecycle Status Product Registration Product Selection Toolbox Repairs Sample Code Library Software Activations View All
Case Study
Recent ActivityRecent Activity

Pohokura Sets the Standard for Remote Operation and Sustainability

Share This:

LinkedInLinkedIn
TwitterTwitter
FacebookFacebook
PrintPrint
EmailEmail
Main Image

Challenge

  • To develop an unmanned site for the Pohokura production station

Solutions

  • Integrated automation and control solution
  • MCCs - Two low voltage motor control centers were designed and installed for production station control
  • Network capabilities
  • DeviceNet - provides reliable communication and the Automatic Device Replacement feature reduces downtime with automatic download of device parameters

Results

  • Remote operation
  • The integrated automation and control solution allowed the Pohokura production station to achieve zero normal operating presence
  • Excellent control, fault diagnostics and network capabilities were achieved with measures to avoid costly downtime
  • Safety and environmental excellence
  • Environmental excellence was achieved by using horizontal drilling to insert a pipeline behind the cliff face and underneath the foreshore to preserve the local coastal environment

Background

Natural gas is a very valuable resource. It is an environmentally friendly, clean fuel when compared to other fossil fuels. Natural gas is more efficient with 90 per cent of production reaching the point of consumption.

The efficiency is constantly improving with technological advances in extraction, transportation and storage techniques.

The transportation system for natural gas consists of a complex network of pipelines, designed to quickly and efficiently transport natural gas from its origin to areas of high demand.

The Pohokura field, offshore from Taranaki, is the country's largest natural gas resource, owned by a joint venture between Shell, Todd Pohokura, and OMV New Zealand.

The production station is operated by Shell Exploration NZ which uses the services of Shell Todd Oil Services. The Pohokura field natural gas is fed into the national grid network.

The first commercial gas flowed from three onshore ‘extended reach' drilling wells in the Southern part of the field in September 2006.

In March 2007, gas and condensate began to flow from the first of five offshore wells via an undersea pipeline back to an onshore production station at Motunui.

Challenge

Developing an unmanned site— where operations are monitored from a control room in New Plymouth— required the combined expertise of engineers, consultants and systems integrators.

The Pohokura design contractor, Transfield Worley, appointed long-standing systems integrator partner Engineering Control Limited (ECL).

One of the requirements for remote operation was that the motor control centres be integrated into the main plant control system on an intelligent network so that the information from the gas station could be fed back to the control room.

Transfield Worley based the new system on the DeviceNet network together with the Allen-Bradley ControlLogix® platform from Rockwell Automation.

Another requirement was that the status of power switchgear at the 400V MCCs and the plant 11kV main switchboard had to be available in the control room and this switchgear had to be operable from the control room as well.

This was achieved by hardwiring the switchgear to discrete I/O in the ControlLogix.

Being able to operate the switchgear from remote is also a welcome safety feature as it removes the need for local operation and so does not expose operators to possible harm from such things as arc flash as may occur if there is a switchgear fault or failure whilst it is being operated.

Establishing A Remote Operation

Pohokura produces over 45 per cent of New Zealand's natural gas which is reticulated around the North Island to industry and domestic consumption.

“By using Shell's technical expertise we set out to deliver a highly reliable unmanned gas production station with a small environmental footprint,” said Paul Brown, Pohokura Operations Engineer.

“A priority for us was to deliver the project on time, on budget and safely, with no harm to personnel or any adverse effects to the neighbours or the environment.”

The operational philosophy for the Pohokura production facility was to establish an unmanned site with zero normal operating presence (ZNOP); plant operation would be performed off-site from a remote control room in New Plymouth using a Distributed Control System (DCS).

Remote operation is an ideal way to help keep personnel safe and away from potentially hazardous equipment, but its operational success relies on excellent control, fault diagnostics and network capabilities “DeviceNet provided a network solution that could help provide reliable communication and also had the added feature of Automatic Device Replacement (ADR), allowing for reduced downtime with automatic download of device parameters,” said Prasad Nory, Industry Manager, Rockwell Automation.

ADR consists of configuration and auto-address recovery which effectively lowers maintenance requirements. Operating 24 hours a day, 7 days a week, Pohokura has a scheduled proactive maintenance day every month to identify and deal with potential problems.

The Pohokura Blueprint

The Transfield Worley electrically engineered design was the basis for a completely integrated solution that required the capabilities of leading board builders, Switchbuild Ltd.

The Pohokura solution evolved around the development of two low-voltage motor control centres (MCCs). Two 2.5MVA transformers feed into the first low-voltage MCC via 4000A Air Circuit Breakers (ACBs). Power from the first MCC is then fed through to the second low voltage MCC.

The intelligent MCC design utilised the DeviceNet network, communicating to the DOL start motor starters for control and monitoring.

The E3 plus smart overloads provided motor protection that very closely matched the motor operating characteristics with the enhanced protection capabilities such as earth fault, stall, thermistor and loss of load that are normally provided by much more expensive motor protective relays.

An Allen Bradley ControlLogix Programmable Automation Controller is used to provide the comprehensive monitoring and control of the MCCs and feeds back information to the distributed control system.

“The Allen Bradley solution provides advance load protection. The client has the ability to analyse the performance of their motors and view faults, all in an integral unit that is visible from the distributed control system,” said Donald Liddell, Manager, Switchbuild.

To avoid costly downtime at Pohokura, ECL developed and incorporated switching Controls in the PAC in the event that power is lost from one of the two 11kV incomers.

According to Peter Huitema, Engineer ECL, “Normally when supplies switch over you lose power, even if it's just a few milliseconds, the motors will shutdown.

To avoid this, we determined how many seconds the motor can be with no power without causing any damage.

We used inertia to keep motors running for up to 1.5 seconds, to allow time for the other supply to switch over. By programming this information into the Control System we were able to avoid costly shutdowns.”

Environmental Excellence

The implementation of state-of-the-art engineering has enabled the Pohokura plant to be operated remotely.

“Safety to personnel and the environment take an even higher priority in a remote operation so plant and components must work reliably with minimal maintenance.

All components chosen for the Pohokura project had to have proven reliability,” said Paul Brown, Pohokura Operations Engineer.

To achieve environmental excellence, modifications were made to the original design of the field.

Horizontal directional drilling technology was used to eliminate the need to have a pipeline from the onshore production station out to the offshore platform that would have run over the cliff face and across the foreshore.

Instead—and as a first for New Zealand—a pipeline was inserted behind the cliff face and underneath the foreshore, so there was no visible or physical intrusion and the local coastal environment was preserved.

The plant's processing areas are built in concrete bunds. Before the water is drained into the stormwater treatment systems, an absorbent skimmer removes residual floating hydrocarbons.

Stormwater is further processed via a specially designed “wetland” where plants are utilised as a natural bio-filter. Filtration through the wetlands removes any residual hydrocarbons.

These environmental features resulted in Shell Pohokura receiving a sustainable development and technical innovation award from the Taranaki Regional Council in 2010.

Reaction to the integrated automation control solution from Rockwell Automation has been positive. “There have been no problems with the PACs from Rockwell Automation in the five years of Pohokura operation—our objectives have been fully satisfied in terms of budget, timing, personnel safety and environmental sustainability,” concludes Brown.

The value of the successfully operating remote control operation at Pohokura has been realised and as such, is currently undergoing an expansion to create another plant using the same easily extendable solution provided by the Rockwell Automation Integrated Architecture system.

Published 1 May, 2013

Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

Loading
  • Technical Question
  • Chat Technical Support
  • Phone Support
  • Contact Sales
  • General Questions
  1. Chevron LeftChevron Left Home Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Discover
  • The Connected Enterprise®
  • Create Your Account
  • Case Studies
  • Events
Information for...
  • Distributors
  • OEM
  • System Integrators
  • Encompass Partners
  • Investors
  • Career Seekers
Contact Us
  • General Questions
  • Technical Questions
  • Local Sales & Service
  • Pricing & Availability
  • Report Ethical Concerns
  • Customer Experience Survey
Site Information
  • Legal
  • Privacy Policy
  • Cookie Preferences
  • Terms of Use
  • Trademarks
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language Change Country
India/English

Keep Updated With Us

Sign up to receive our latest headlines for free.

Stay Informed Now
Follow Us
BlogRockwell Automation's Blog
Copyright ©2021 Rockwell Automation, Inc.
Home