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"Extra" program, version 6.0
 
    Using the "Extra" software helps to:
  • Create an up-to-date system of accounting and analysis of pipelines;
  • Create a descriptive model of hydrodynamics and corrosion activity of working media flows, both in numerical table form and in graphical form, on a pipeline system diagram;
  • Find all the "bottle necks" that are vital for accident-free operation of the piping system;
  • Elaborate and substantiate the plan of expeditious measures aimed at maintaining high in-service reliability of pipelines
 
    The program is designed for use in processing departments, corrosion protection services, engineering supervision departments, mechanical supervisors' departments, environmental and other services. Thus, the program combines the activities of all services related with pipeline maintenance, creating favorable conditions for easy exchange of operative information.
 
    In comparison to computerized pipeline accounting storage systems our software product has a great analytical potential. The calculation methods used in this program are based on the materials of the IPTER and other scientific research institutes' research activity as well as on certified documentary data and sectoral GD.
 
    While developing the program, we took into account numerous requests of oil and gas producing enterprises of Volga region and Western Siberia. The program is supplied to customers in its network version based on client/server architecture (Oracle DBMS), which allows geographically separated users to use a common Database simultaneously. Using of a common Database (DB) by all members of an enterprise allows to integrate all information on pipelines received by specialists of different departments on site. The information necessary for the following purposes is entered in the Database:
  • pipeline certification,
  • pipelines current state analysis,
  • pipelines accident rate analysis,
  • corrosion inhibitors protection,
  • corrosion monitoring,
  • various diagnostic inspections.
The program allows using of inputted account data for displaying of a production piping system and its elements, including nominal ones, with location reference.
 
    Calculation modules of the program provide ample opportunities for conducting wide analytic research of inputted data, namely:
  • hydraulic calculations of three-phase oil emulsions for the entire field (including closed loops) based on two independent methods
  • determination of gas-liquid flow structures using a Baker diagram
  • calculation of predictive corrosion rate and corrosion risk areas according to six domestic methods and two methods recommended by the American Petroleum Institute (API)
  • calculation of corrosion inhibitors concentration at all objects of a pipeline network
  • primary statistical data processing on completion of diagnostics
21 calculation procedures altogether were realized in the program.
 
    The program is designed for operation under Windows 95/98/NT4.0/2000. The program is provided with a contextual data support with a description of all methods used in calculations.
 
    At your request we can arrange a presentation of the "Extra" software product.
Features
 
The program allows the user to work in the following areas:
  1. Computerized certification of pipelines according to GD 39-132-94 with auto-formation of all necessary reports (18 forms altogether, including pipeline layout). Additional reports:

    • "Non-Classified Failure Report"
    • "Non-Classified Failure Log"
    • "Oil-Field and Reservoir Pressure Maintenance (RPM) Systems Failure Report" according to the forms of the GD 39-132-94 applications 15 through 17
    • pipeline inventory reports
    • pipelines age structure reports
    • audit schedule report
    • pipeline "dead" oil residue report and many others

    While printing out a report, you can also print out scanned copies of the documents and image files of pipeline layouts stored in the Database with a reference to correspondent pipelines.

  2. Registration of pipeline characteristics:

    • pipe part categories
    • operational and geometric characteristics
    • field position and topography
    • crossings
    • materials and component parts used
    • electrical and chemical protection
    • land ownership

  3. Registration of accidents, repairs and inspections.
  4. Registration of receipt and consumption of reagents used in pipeline maintenance.
  5. Registration and analysis of influence of chemical treatment of wells on pipeline maintenance.
  6. Analysis of pipeline structure for any selected period in any parameter combination:

    • by shops
    • by pipeline function
    • by a class of a transported medium
    • by water-content of a transported medium
    • by a sort of corrosion inhibitors used
    • by pipe diameter
    • by pipe commissioning date
    • by pipe manufacturing plant
    • by estimated corrosion risk and other user-defined parameters

  7. Analysis of oil and gas producing enterprises equipment accident rate:

    • Analysis of an oilfield corrosion condition for any selected period in any parameter combination. Such analysis is aimed at estimation of influence of these factors on an accident rate:

      • by shop equipment accident rate
      • by pipeline function
      • by a class of a transported medium
      • by water-content of a transported medium
      • by an availability of anti-corrosive inhibitor protection
      • by pipe diameter
      • by pipe commissioning date

    • Screening of the most corrosion-hazardous pipelines based on user-selected criteria (in any combination):

      • by a number of accidents at an object
      • by a specific frequency of accidents per analytic year
      • by an average specific frequency of accidents per three analytic years

  8. Direct and reverse hydraulic calculation of water, oil and gas flow (based on two methods) simultaneously for the entire field. Calculations for parallel and looped sections of oil-field and RPM systems.
  9. Detection of corrosion-hazardous parts of the oil-field system (based on six methods). Detection of pipelines prone to corrosion erosion.
  10. Determination of a predictive corrosion rate based on a flow chemical analysis and hydrodynamics data (three methods).
  11. Determination of a current nominal concentration of corrosion inhibitors for each pipeline of the oil-field system, knowing the configuration and the productive capacity of batch meters.
  12. Calculation of pipeline categories and diameter screening according to GD 39-132-94.
  13. Development and economic analysis of inhibition procedures.
  14. Corrosion monitoring scheduling.
  15. Determination of a pipe length sufficient for an associated oil demulsification.
  16. Registration and statistical processing of data on corrosion control units: gravimetry, profilometry and electrochemistry. Data conversion from Monicor-2 information tanks to the "Extra" database.
  17. Plotting of a scalable chart of a pipeline network and its typical elements based on pipeline coordinates and indicated distances to the elements entered in the Database. An option of retrieving and editing of all inputted information by a user-selected object from the chart. The user may choose to display:

    • Pipeline name
    • Hydraulic parameters of each pipeline: length, diameter, wall thickness, elevation difference, flow rate, water cut, pressure (according to calculation and source data)
    • Corrosion-hazardous parts (based on different calculation methods)
    • Inhibitor protected parts (based on calculations)
    • Parts with excessive specific loss of pressure (based on calculation)
    • Parts with different flow speed
    • Accidents with location reference and an option of a layer-by-layer displaying by one or several causes
    • Valves (opened and closed valves are marked with different colors)
    • Corrosion control units
    • Corrosion inhibitor batch meters
    • Crossings via existing engineering service lines and natural obstacles
    • When there is no indication of pipe intersection on the graphical chart the intersection spot is marked automatically with an arc on one of the pipes

  18. Graphic representation of dependences:

    • "Number of accidents - time" (a column chart with a classification by cause and a selection by a time period)
    • Pipeline route profile with accident marks (for accidents caused by various reasons), valves, crossings, corrosion control units' installation locations, dates of commissioning of different profile sections
    • "Corrosion rate at corrosion control units - time" chart with an indication of average values and a confidence interval
    • "Corrosion rate according to corrosion gages - time" chart (with a feature for determination of average, maximum and minimum values and a confidence interval for each selected time period)
    • Equivalent annual expenses chart for pipeline maintenance expenses with a feature for calculation of an optimal service period before replacement according to three options (each considered optionally with and without inhibition)
    • Residual pipe wall thickness according to thickness gaging results
    • and other charts and graphs

  19. Comparison of accident data with corrosion-hydraulic calculations and diagnostic equipment readings, including corrosion control units readings.
  20. Economic analysis of effectiveness of different variants of pipeline reliability enhancement (use of new materials, modification of pipeline geometry, inhibition). Assessment of an economically feasible replacement age for pipelines in accordance with accident rate prediction based on retrospective data or calculated dependences.
  21. Our software is supplied with a built-in context help.
 
A replication module has been developed for low-bit-rate networks. The module allows to synchronize Databases throughout the enterprise. A network version of the program is enhanced with an Iproxy module for automatic update. The program is updated at all workplaces concurrently with a database update on the server.
Calculation module
 
    Hydraulic calculation is based on unstable three-phase emulsions calculation procedure, developed by V.F. Medvedev. (see "Medvedev V.F. Collection and Preparation of Unstable Emulsions at Oil-Fields", Moscow, 1987, "Nedra"), and a procedure developed by G.G. Kornilov (IPTER) and added to GD 39-3-1034-84, taking into account thermophysical dependences of hydraulic parameters (viscosity, density, etc.).
 
    The program allows calculating oil-gathering systems with closed loops of any complexity. The user doesn't need to specify these loops as the program detects them automatically before each set of calculation. Closed loops are calculated based on a high precision procedure developed by V.G. Lobachev. The calculation covers the entire process flow of the deposit beginning from wells (clusters) to stock tanks, taking into account the topography and the ground temperature.
 
    Methods developed by VNIISPTneft (IPTER), UNI, GrozNII, BNI and SevKavNIPInefti and API are used for the detection of corrosion-hazardous parts of an oil-field system.
 
    In addition, the program allows the following calculations:
  1. Calculation of a maximum local corrosion rate of oil-and-gas pipelines based on a chemical composition of water and hydro-dynamic parameters of a pumpover according to GD 39-0147323-339-89-R.
  2. De Waard - Milliams' CO2-based corrosion rate calculation with consideration to a medium flow.
  3. Prediction of the speed of pipeline corrosion leading to frequent pipe leaks, applied to the conditions of Western Siberia, according to the IPTER's newly developed method.
  4. Calculation of a flow velocity critical for corrosion erosion, according to ANSI/API RP14-91.
  5. Calculation of corrosion inhibitor concentration at all piping network objects during a continuous injection of inhibitors from stationary feeding points.
  6. Calculation of a pipe length sufficient for an associated demulsification.
 
    Application of different methods allows to determine the most appropriate method for a given deposit, based on accident data.
 
    Table forms for accident rate and pipeline calculations and analyses are user-specific. The user can select necessary table fields at his discretion. Resulting calculation forms are represented by 45 indexes; those for accident rate and pipeline analysis - by 22 indexes.
 
    Resulting tables are supplied with a feature for data sorting by any column. Data from all the table forms can be exported to MS Excel.
 
    The program is furnished with a functional block of economic analysis of effectiveness of different variants of pipeline reliability enhancement (use of new materials, modification of pipeline geometry, inhibition). This functional block allows:
  • to calculate optimal pipeline replacement age
  • to compare different variants based on failure flow and corrosion rates predictive models
  • technical and economic assessment of optimal configuration and productive capacity of batch meters in oil-field multibranch networks
The assessment is based on modern economic views and a unique approach to economic problem solving.
Sample reports available in Extra 6
 
  1. Pipeline flow diagram visualization
  2. An "Inventory" report form
  3. An "Age Composition Data" report form
  4. A "Failure report" report form
  5. A "Failure Log" report form
  6. Accident rate sorting criteria selection form
  7. Accident rate sorting results with a failure chart
  8. Corrosion-hydraulic calculation results
  9. Corrosion Control Unit (UKK) data registration form
  10. Import of corrosion rate data to the UKK data registration form from the Monicor-2 corrosion gauge.
  11. Interval assessment of corrosion rate based on the Monicor-2 corrosion gage data
  12. Corrosion gage indication chart
  13. Schedule of the Corrosion monitoring system maintenance
  14. "Inhibition procedures" calculation form
  15. Inhibition procedure analysis
  16. Data input form for a cost of 1 km of pipes
  17. Data input form for operational characteristics of three methods of economic assessment
  18. Pipeline construction estimated cost
  19. Value engineering visualization form
  20. Pipeline data input form
  21. Object (pipe part) data input form
  22. Accident data input form
  23. Pipeline route profile and space coordinates input form
  24. Reagents (corrosion inhibitors) registration form, general data
  25. Reagents (corrosion inhibitors) registration form, characteristics
Additional information
 
 
Customers
 
    The program was installed in its network version at OAO "Var'eganneft", OAO "Belkamneft", "PechorNIPIneft'", OAO "Rosneft-Purneftegaz", OAO "Orenburgneft", ZAO "Kormako", OGPD "Komsomolskneft", "TNK-Nyagan", "Nizhnevartovsk Oil-Production Enterprise", "Yugraneft Corporation", "Samotlorneftegaz", "Saratovneftegaz", "TNK-Nizhnevartovsk", three OGPD OAO "Surgutneftegaz" and others.
 
    At your request the program can be supplied with new advanced calculation and analysis options as well as with modules of conversion of a Customer's wells database into an Extra database for updating of the process design source information. There is also an option of a direct connection (data transfer) to programs working with industrial Databases and operated by Oracle servers, MS SQL servers, etc.