Worlds #1 Energy source

Considering daily and yearly consumption volumes, oil is still second to none as a world-leading energy source.

In 2021 89,9 million barrels of oil were produced daily. The USA alone daily production equaled about 18.6 million barrels. 

Despite the fast-paced oil production, the reserves are running low and, according to the latest reports will be sufficient for the following 47 years. 

Oil producers are continuously seeking and investing in new sources and solutions aimed toward the renewal of production capabilities that ensure the maximum energy supply possible. 

Oil Extraction

Despite the popular belief of numerous underground oil fields available 10 km underground and that by drilling holes, one would dip in the pool of oil and the extraction can start - the process of oil extraction is much more complex. 

Oil can usually be found underground in hollow soil at pore levels and is raised to the ground and collected (alongside other materials like water and gas) into collecting stations through pipes where it is subsequently processed and sent to refineries.

Beam Pump or so-called Pumpjack

One of the most popular ways of oil production/extraction is production from the ground with so-called pumpjack machines. The “horse head” look-a-like machine that you can see on almost all oil fields.

Even though this is the most common way used for oil extraction, it is not without challenges and obstacles. If a pumpjack is not set up and managed properly, its work can be entirely counter-productive. 

In cases of wells not so rich in oils, a continuous inflow of the oil and a synced operation of a pumpjack are crucial and the synchronization part is hard to be obtained.

Most of the pumpjacks functioning to the day are old, not automated machines that are not upgraded with new technologies. In rich wells, they are working 24/7 with occasional pauses.

In case when the well is not as rich in oil, the pumpjack is set to work at a particular time for a certain period. In cases when there is no oil in the well, the pumpjack will work nevertheless - risking the inflow of sand, dirt, or any other material with the potential to cause extensive damage leading to an expensive rehaul. The rehaul requires the pumpjack to be out of order for some time, again causing additional financial loss. 

This instance particularly occurs in wells that are not equipped with sensors and monitoring or advanced status reporting. The pumpjacks are working with no clear data from the well in defined time terms, which leads to sand appearance, the collapse of the string, frequent overhauls, or pump destruction.

Sucker Rod Pump Automation

The most common solution to this problem is technologically advanced, sensor-rich systems that enable the synchronization of a pumpjack unit with an oil flow by helping to determine the precise speed for the pumpjack to run. Thus, oil extraction becomes fully automated.

Automation cuts maintenance costs improve production and enable proper management and monitoring. Automation also decreases the overhaul periods as the production improved while combined with sensors and deep hole diagram reporting.

Oil well automatization enables continuous production by regulating the work pace and a proper mechanical shutdown in cases of downhole wells not being eligible for production.

Duplico provides advanced technological solutions for oil well automatization, partnering with two most popular and renowned companies - UNICO and Lufkin.

As a certified partner, we have knowledge, expertise, and experience in good automation utilizing both Lufkins and UNICO product suites.

LRP Units - A great alternative to Pumpjack units

LRP (Linear Rod Pump) units are great alternatives to standard pumpjack units. LRP units enable competitive and safe production in a compact linear design.

The Linear Rod Pump units are patented technology from UNICO and as such, they have many advantages over the standard Sucker Rod Pumps horse-head look-alike units. Among others LRP units have minimal site impact, do not require a building permit, and are much easier to install and transport in case users want to move them. LRP Units can be easily fitted in any environment, including cities because of their small footprint. 

They are an ideal solution for shallower wells, from which large units can no longer extract anything due to their constraints. 

In combination with UNICO's patented sucker rod pump technology for autonomous oil well optimization, they represent a great alternative.

UNICO's LPR units are easier and cheaper to maintain because they come with advanced technology that requires zero sensors and all readings are done from the motor and VSD drives it itself.

Despite being sensorless they have all the features such as downhole equipment protection, fluid level controls, automatic pump clean mode, well reporting, surface and downhole predictive dynacards, remote access, and much more.

Duplico recognized this and in partnership with UNICO, we installed the UNICO LRP system in the Croatian Oil and gas company INA.

After the installation of 13 LRP units, the recorded oil production skyrocketed to 50%, making this project a huge success. 

The valuable project information was a subject of a master thesis done by the University of Zagreb, Faculty and Mining, Geology, and Petroleum Engineering students, raising awareness of this technology even more.

Let's talk.

Do you have a project or need help to increase or automate your oil production?

Send us a message and some of our engineers will get back to you ASAP to discuss the project's requirements in further detail. 

Natural gas consumption specifics

Natural gas is one of the most widely used energy sources. It is used for industrial, commercial, and residential sectors – mainly for heating, electricity generation, and multiple industrial uses.

Unlike other conventional energy sources such as oil or coal that have relatively low transportation costs, in most cases – natural gas transportation requires higher investments. As a result, local and international markets are based on long-term contracts and one of the risk factors for natural gas distributors is demand uncertainty.

Therefore, accurate forecasting of the demand for natural gas is crucial for the efficient management of this resource.

Global natural gas consumption is expected to grow at an annual average rate of 0.8% from 2022 to 2025.

One of the particularities of natural gas consumption is that it is a system whose dynamics depend on meteorological data, day-to-week, year-on-year, and growth in the number of customers.

The permissible losses prescribed by law in the gas grid amount to a maximum of 3%, and all losses above, negatively affect the financial aspect of the distributor.

Forecasting of natural gas consumption

The Ordinance on the organization of the natural gas market has introduced significant changes for suppliers in the distribution system of the Republic of Croatia. The fundamental change is the introduction of nomination or delivery of forecast hourly gas consumption for the next gas day.

Duplico, in cooperation with the PTMG and the Faculty of Electrical Engineering in Zagreb, has developed an application for making such nominations based on neuronal networks.

Neural networks have the feature of a universal linear approximator, require a relatively small amount of historical data, and have the ability to adapt, which eliminates problems arising from natural gas consumption, small amounts of historical data, increased users, and possible reductions.

Points of download for gas consumption data

As the distribution areas of an individual supplier are divided according to the measurement-reduction units of the transport system operator, it is necessary to carry out measurements of gas consumption at these points.

This ensures the comparability of measurements with those of transport system operators and facilitates the processing of the data received for entry into the nomination system.

The consumption of natural gas by large consumers, mostly industrial plants, depends primarily on the state of production, and can not be linked to predictable factors of natural gas consumption. 

Therefore, a large-scale consumer encoder connects the meter to the day-to-day delivery to the large consumer and supplier of hourly consumption data.

Data download method

Data from readings and measurement-reduction cells are performed using telemetry cells that have the ability to connect to a closed VPN network with the static IP addresses of each individual cell.

Connectivity within the VPN network is realized through the GPRS / UMTS network of mobile operators, avoiding the installation of expensive telecommunication equipment and achieving secure, fast, and inexpensive data transfer.

For the successful design of the nomination, it is necessary to know the meteorological conditions that governed a certain reading of natural gas consumption. 

For this reason, an automated meteorological station is connected to the VPN network in the supplier area and sends its measurements to the supervisory control center every hour. 

The available meteorological stations are:

• air temperature
• relative humidity
• wind direction
• wind speed
• amount of precipitation
• cloudiness

Factors influencing gas consumption

Natural Gas Consumption is a system dependent on meteorological data, day to a week, seasonality, and the growth or decrease in the number of users.

The greatest influencer on gas consumption is the temperature, followed by precipitation, cloudiness, and winds.

However, depending on the geographic area and season where the supplier is located, different meteorological sizes gain or lose importance.

Nomination system description

The nomination system consists of fifty neural networks, polynomial functions, and a set of vague rules for decision-making.

The main problems that emerged in the design of the nomination program were the lack of archives of historical meteorological data on natural gas consumption and the conditions under which such consumption occurred.

For this reason, it is necessary to collect the data and create the archive before the nomination program is started. At low consumption in the system especially in the summer period, consumers that usually don’t count as big spenders have a significant impact, but they have a large consumption in comparison to household consumption. 

Such consumers are primarily asphalt bases and dryers.

Experience has therefore shown that appropriate solutions for the nomination of planned natural gas consumption can not be purchased on the market as a universal and pre-prepared.  

It is both important and beneficial to have long-lasting cooperation between the designers of the nomination program and the users in order to define, see and incorporate all of the particularities for the observed distribution area.

Let's talk.

You are looking for an accurate natural gas consumption prediction method?

Send us a message and we will get back to you ASAP to discuss all requirements in further detail. 

Industry Control Systems Play Important Role In Today's World 

Supervisory control and data acquisition (SCADA) systems are used to assist in automation monitoring, management, and analysis of the operations of industrial devices and processes. SCADA systems thus are widely used throughout various industries.

SCADA systems are a combination of software and hardware components that enable the real-time collection of data derived from industrial equipment remotely and on-site. A SCADA system enables remote control and monitoring of industrial sites such as wind farms, water and wastewater plants, oil wells, water supply stations, and many others.

SCADA provides valuable information to stakeholders. The system can be used to improve the performance of industrial plants, monitor plant efficiency, and mitigate errors and downtime through real-time messages received from the system.

In a modern fast-paced industry environment, SCADA systems are the key to efficiency in running industrial plants due to their fast collection of essential data. Timely information received from such systems allows better planning of resources in industrial processes.

The connecting link of SCADA architecture is programmable logic controllers (PLCs) or remote terminal units (RTUs). Those are microcomputers that interact with equipment (also called field devices) on the one hand and HMIs (which are human-machine interfaces) on the other. HMIs are also called graphical user interfaces

Duplico Automation Solutions

Duplico operates in numerous industries, each with its specifics while serving many different customers within the industries.  The variety of both demands specialization that goes beyond a single supplier for SCADA and PLC solutions.

There are many SCADA system framework vendors on the market such as Siemens WinCC, GE iFix, PcVue, Schneider Electric Geo SCADA, SystemPlatform and others.

We can offer our clients turnkey automation solutions with the following supplier solutions:

• Siemens WinCC
• Schneider Electric geo SCADA
• SE System platform
• PcVue
• General Electric iFix

PLC expertise and knowledge:

• Mitsubishi
• Siemens S7 family (Siemens S’-1200, S7-400… popisati)
• Schneider Electric family
• Allen Bradley

Duplico's extensive experience in system integration, a well-trained team of engineers, and applied sophisticated technologies - guarantee the skills and competencies necessary to provide the best solution for your automation problem.

Our partnership with some of the top suppliers in the field of industrial automation (Siemens, Schneider, Mitsubishi, Alen Bradey, and others) allows us to install the best hardware and software for each custom system while keeping a competitive price.

Lets talk.

You got a project or a need for automation in your plan or production facility? Contact us and our engineers will get back to you ASAP to discuss the project's requirements in further details.

The heart of every plant and facility

Regardless if you operate an oil and gas well, a wastewater plant, an apartment building or a pharmaceutical manufacturing facility - it is inevitable for you to come in contact with electrical switchgear. 

It is the core of every industrial process and plant.

As a technology company, we have developed one of the most advanced facilities for assembly of control and power switchgears in the Central and East-European countries. 

Regardless of the size, scope and requirements of the project towards electrical switchgear - we can supply it. Small low-voltage switchgear, a modular switchgear, control switchgear or an 8000A power distribution certified switchgear we have a solution to fit your needs

Through a comprehensive project portfolio, more than 2 decades of experience and numerous certifications and licenses for solutions such as Siemens SIVACON S8, Schneider Electric OKKEN, Cubic, Logstrup, Eaton & ABB, Duplico's engineering team has gained invaluable knowledge of power distribution systems.

Duplico MOD center - Your reliable panel building partner

Our uncompromising commitment to quality workmanship and engineering excellence ensures that every electrical cabinet is designed and manufactured to exact specifications and delivered on time, every time.

We produce various types of low-voltage electrical cabinets tested according to standard EN 61439. 

Using 3D modeling tools, and utilizing vast knowledge and experience our team of engineers can create a competitive solution according to the specifications and customer requirements, thus making us reliable OEM and turnkey projects based partner. Click here for more information.

Our dedication to the process of assembly of electric switchgear is both a profession and inspiration. The business investments we made through the years were and are largely directed toward extensive research, development, and testing of new methods and technologies. 

Our finished projects portfolio showcase the added values gained through those investments - a large base of fully installed and appropriately tested LV switchgears built through a clear process of design, modeling, assembly, and QC.

Video overview of our facilities and our assembly process.

Let's talk.

Our approach is based on collaboration with end users, consultants, and contractors through every step of the design, production, and installation process.  Duplico LV distribution cabinets are completely designed, manufactured, and technically tested in Duplico.  No matter how big or small your requirements are, contact us today and lets see how we can help you.

What are explosive zones? 

Explosive zones or explosive atmospheres can commonly be found in industries and facilities such as oil and gas, chemical factories, refineries, gas storages, paint and varnish workshops, etc.

They are defined as space or zones around and next to flammable gasses, oil vapor, gas vapor, vapors from the paint, chemicals, and any potential explosive material or substance.

In explosive zones, one has to pay special attention to appropriate, safe work conditions and installations as any wrongdoing can result in massive damage or a loss of human live/s.

There are 3 sub-types of explosive zones, defined regarding an assessment of the frequency of the occurrence and duration of an explosive gas atmosphere around the explosive matter.

• Zone 0 - is the area where an explosive gas atmosphere is present continuously or for long periods
• Zone 1- is an area where an explosive gas atmosphere is likely to occur in normal operation
• Zone 2 - is an area in which an explosive gas atmosphere is not likely to occur in normal operation. In cases, if it does occur, it will only exist for a short time

To each particular hazardous area zones, a different set of standards and rules apply for the equipment that is eligible for installation.

Standards are drawn for different sets of protection concepts and, due to an immense focus on safety, have been further developed through the years.

Inspection & Testing

Hazardous area zone inspection and electrical installation testing are comprehensive and detailed sets of specific procedures that require knowledge and understanding of all possible catastrophic outcomes in case anything goes wrong.

The procedure steps include a detailed check of all devices present within the hazardous areas, according to standards and requirements applicable to a particular area.

The testing includes a check of circuit protection elements and requires a great number of visual checkups and confirmations.

Assessment and testing of hazardous zone installations, therefore, requires a licensed and certified professional.

Measurements and checking of the impedance of a fault loop have to be carried out by a company authorized by the Ministry of Internal Affairs (MUP).

Testers from an authorized company that performs testing have to among other things, have appropriate professions, and must be medically fit and professionally trained through certain professional seminars, e.g. Specialist education in the field of explosion protection - Ex 1 (basic level) or Specialist education in the area of ​​explosion protection - Ex 2 (knowledge renewal), depending on requirements.

Installations are tested with special instruments, followed by a full report on procedures and findings.

A certified tester is also required to wear antistatic protective clothing.

Duplico employs a team of professionals, certified for hazardous zone testing and with appropriate knowledge and experience crucial to this comprehensive approach.

Let's talk.

Regular explosive zones testing results in increased safety according to all standards. You are looking for a certified company?

Send us a message and we will get back to you ASAP to discuss all requirements in further detail.

For the management system according to ISO 14001: 2015

Environment is a surrounding in which an organization operates. The environment includes air, water, soil, natural resources, flora, fauna, humans and their mutual relationships. ISO 14001: 2015 Environmental Management Systems norm – The requirements in the operating instructions state requirements for an environmental management system that will enable the organization to develop and implement policies and targets that take into account legal requirements and information on significant environmental aspects. The main purpose of this international standard of support for environmental protection and the prevention of polution is in balance with socio-economic needs.  Among other requirements, the norm also prescribes policy requirements and environmental managment goals.

The management of an organization wishing to introduce an environmental management system in accordance with ISO 14001: 2015 must define the environmental management policy of the organization and ensure that such policy is consistent with the nature, scope and impact of its activities, products or services on the environment.  It must also ensure that policy involves the commitment of the management to permanently improve and prevent pollution and includes the commitment of compliance with the corresponding legal requirements and other requirements that the organization has commited in relation to its environmental aspects. Environmental management policy must provide a framework for setting up and reviewing general and individual goals. The policy prescribed must be accessible to the public and must be communicated to all persons working in the organization.

The organization must establish, apply and maintain documented general and individual goals at the appropriate functions and levels within the organization.  General and individual goals must be measurable, whenever possible, in accordance with environmental management policy, including commitment to prevent pollution, compliance with the relevant legal requirements that the organization is commited to and commitment to lasting improvement.

For energy management system according to ISO 50001: 2018

ISO 50001: 2018, Energy Management Systems – Requirements for Operating Instructions, provides requirements for the establishment of an energy management system (EnMS) in industrial plants, commercial, administrative and state buildings and entire organizations. It is estimated that this norm, which is geared to wider application in all national economic sectors, will affect around 60% of world energy use.

Energy is of key importance to the organization’s buisness and it can be a huge expense, regardless of their buisness. Apart from the economic costs of energy consumption for the organization, energy consumption can also cause damage to the consumption of natural resources and the negative impacts on climate change.

As with all ISO system management norms, ISO 50001 is designed to be applied to any organization, regardless of its size or buisness, regardless of whatever it is in the public or private sector, and regardless of its geographic location.

ISO 50001 is based on the model of the ISO management system that is applied in the standards of the management systems. In particular, the plan-do-check-act (PDCA) process has been specifically adopted for the continuius improvement of the energy management system. This enables the integration of energy management organizations with other organizational quality management systems, the environment, etc.

That approach is described by the management model as follows:

Plan: carries out an energy rating and establishes a baseline, energy performance indicators (ENPIs), long-term and short-term goals, and action plans necessary for obtaining results that will improve energy features in accordance with the energy policy organization.

Do:  carries out plans of action on energy management.

Check: observe and measure the key features of operations that determine energy features in relation to energy policy and long term energy policy goals and report on results.

Act: take action to continuously improve the EnMS feature.

For the management system according to ISO 9001:2015

ISO 9001 certificate confirms successful compliance with international standard ISO 9001 Quality Management Systems Organizations that hold the ISO 9001 certification demonstrate a successfully implemented quality management system in their organization. Organizations can have established a quality management system in accordance with the requirements of ISO 9001, but only with certification procedures prove that this system is successfully implemented and thus their clients and other market participants can trust the introduces quality management system.

If you belong to organizations that want to maximize your benefit in every way from your management system, you will most likely wonder what additional value you will have and from the system certification itself. Will you benefit from the cost-benefit equivalent of the certification by making use of the helpful remarks of the expert who will evaluate your system? Will your certificate be internationally recognized? Will it enable and encourage you to constantly develop and improve your system?

The introduction of a quality management system should be the strategic decision of the organization. The organization’s environment, the organization’s goals, the products it offers, the proccesses established, the organizational structure and the market in which the organization operates is influenced by the introduction and application of a quality management system. The ISO 9001 standard promotes the acceptance of a process approach when developing, implementing and improving the efficency of a quality management system increases customer satisfaction by meeting its requirements. The ISO 9001 quality management system demonstrates its ability to consistently deliver products that meet customer requirements and requirements of laws and regulations.

Most organizations that invest their time, effort and financial resources in the preparation, implementation and operation of their quality management system will want to obtain an independent certification of their compliance, ie obtain a certificate from a certification company.