Comprehensive Service of the Automated Well Production Metering System for PJSC “MC “UKRNAFTOBURINNYA”: From Unstable Operation to Reliable Control

 

Initial System Condition: Typical Issues of Distributed Solutions

Prior to implementing a systematic service approach, several issues typical for distributed systems were observed:

• hardware and software failures of PLCs during operation;

• periodic loss of communication between the lower level (wellsite controllers) and the upper system level;

• unstable data transmission due to the remote location of facilities;

• accumulation of errors in controller buffers during packet loss (bit loss), which caused equipment to switch to failure mode (STOP) and required technical intervention.

At some wells, controllers periodically switched to failure mode on average once every 2–3 months, creating additional workload for operational personnel and increasing the risk of losing operational data.

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Implemented Solution: Systematic Service Instead of Emergency Response

A comprehensive approach to maintenance of both the upper and lower levels of the Automated Well Production Metering System (AWPMS) was implemented, including regular visits by a service team.

The scope of work included:

• system functionality verification and analysis;

• software diagnostics and adjustments;

• maintenance of well monitoring cabinets;

• inspection of communication and data transmission systems;

• servicing of uninterruptible power supply systems;

• technical inspection and restoration of equipment;

• optimization of router and controller settings.

During maintenance, two controllers required in-depth technical diagnostics. Considering the specifics of the electronic components and the limited availability of certain spare parts, a standard equipment replacement could have resulted in additional costs and downtime.

Therefore, specialists from LLC “EMC TRIADA”, having extensive experience with microprocessor-based equipment, performed engineering restoration of the controllers’ functionality in-house. This allowed preservation of the existing system architecture, reduction of recovery time, and avoidance of premature equipment replacement.

As a result, the service model was shifted from incident-based emergency response to a predictable and controlled technical support framework.

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Data Transmission Optimization: Engineering Approach

A key factor affecting system instability was GSM data transmission under challenging coverage conditions.
 

The following technical solutions were implemented:

• installation of directional GSM antennas;

• adjustment of router settings;

• optimization of data exchange parameters;

• implementation of scheduled controller reboot procedures to prevent error buffer overflow during data packet loss.
   

After implementation of these measures:

• data transmission stabilized;

• the number of errors significantly decreased;

• equipment stopped regularly switching to emergency mode due to buffer overflow.

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Measurable Results

Before:

• periodic controller failures;

• need for regular technical intervention;

• unstable data transmission.

After:

• stable system operation in normal mode;

• failures reduced to a minimum level;

• only 1–2 controllers may require intervention approximately once every six months;

• isolated faults are resolved promptly without critical impact on the production process.

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Optimized Service Intervals

Thanks to the stabilization of system operation, the maintenance interval was gradually increased:

• from once every 2 months

• to once every 3 months

• to once every 4–5 months

Thus, high-quality service maintenance not only improved system reliability but also optimized technical support costs.

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Key Success Factors

The most significant impact on the achieved results was provided by:

• systematic maintenance of well monitoring cabinets;

• optimization of communication and data transmission channels;

• servicing of uninterruptible power supply systems;

• comprehensive understanding of PLC operating logic and the specifics of distributed systems in challenging environments;

• the qualifications of the specialists involved in implementing these measures.

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Long-Term Technical Support

Technical maintenance services for PJSC “MC“Ukrnaftoburinnya” have been provided on a continuous basis since 2021.

Service support practice demonstrates the company’s capability to:

• maintain complex distributed monitoring systems;

• work with equipment of different generations;

• ensure stable operation of Automated Well Production Metering Systems at critical production facilities.