Intelligent Information Technologies for Integrated Management Systems of Enterprises with A Complex Scheme of Gas-Extraction and Processing

Technical Direction for the integrated control and safety management system (ICSS) specifies complex automation of the objects of Kandym group of fields, which yearly production is 8.1 bln. m³ of formation fluid per year. The plant will include all process systems, utility systems, non-process facilities and infrastructure, required for the production of sales gas, stabilized condensate and sulphur.

Gathering system consists of 114 producing wells combined into cluster sites and further combined into gas gathering stations, thus, forming a classic tree structure widely used for hydrocarbons collection systems.

Main objects at the cluster sites are: inlet manifold, fuel gas package, metering separator package, anti-corrosive inhibitor protection system for pipelines, mobile hydrate inhibitor system, and flare system.

Main objects at the gathering stations are: inlet manifold, fuel gas package, metering separator package, product separator, and anti-corrosive inhibitor protection system for pipelines, gas compression unit, and flare system.

CPF consists of the following objects:

Main pipeline is a main gas transport system, including the following:

Kandym group of fields is located in the south of central region of Uzbekistan in close proximity to Turkmenistan border.

Climate is extremely continental with extreme ambient temperatures, severe winds (south and east winds prevail), low humidity and pour precipitations.

In general the terrain is hill-like desert with barkhans and shifting sands. Contract area is featured by considerable seismic loads.

To achieve this goal for the development of an intelligent system of enterprise centralized management Technical center of “Ximavtomatika” LLC (Uzbekistan) with the support of the management of the “LUKOIL Uzbekistan operating company” Company proposed an integrated solution, based on the main criteria of unity of hardware and software platforms of intelligent systems for centralized management of the enterprise. To perform tasks on providing of uniform software, hardware and information provisions of management system and creating ultimately a single global enterprise database were involved the best system engineers, software engineers and network engineers.

The result of this work is the basic design of project, which opens a new page in the history of development of innovative information technologies in the gas industry of the Republic of Uzbekistan.

The essence of the chosen technical solutions for the development of an intelligent system for centralized management of Kandym gas processing plant and a complex of objects of Kandym group of fields is as follows.

ICSS is developed as a single process control system (well - cluster site - gathering station - CPF - sales production export + utility processes) and is implemented based on microprocessor technology, united into single software-hardware complex.

Functionally, ICSS consists of the following major systems:

Probability of system failure has been considered based on the following formula:

Where PFD_AV- Probability of Failure on Demand (Average)

q – Probabilities of system elements failures,

p – Probabilities of system elements working without failures.

So, for the Kandym gas processing plant and a complex of objects of Kandym group of fields PFD summary calculation is provided in below Figure 1.

ICSS has three hierarchical levels and corresponds to modular approach of development. ICSS levels are listed below:

Level 1.

Lower level (Instrumentation) – instrumentation level, intended for gathering of the information on control object and control actions on objects. Instrumentation level includes transmitters, alarm switches, analysers, flow control computers, actuators, motors and other drives, installed at technological equipment and in special rooms, and also include devices which are designated for gathering of the information for power management system.

Level 2.

Middle level (controllers) – programmable logic controller (PLC) level, intended for converting the data from control level 1, processing this information, generation of commands for lower level actuators and preparation this information for upper control level. PLC level includes local controllers and display devices at control cabinets.

Level 3.

Upper level (human-machine interface) – process visualization level (HMI, SCADA, batch processing systems) is intended for gathering of data from level 2, processing and presenting of the data in a convenient form for the operator, and for remote process control using level 2 devices. Level 3 shall have software and hardware to transmit the process data to Customer central office, using existing IT infrastructure (LAN, network firewall, FOCL, etc.);

Kandym GPP and Kandym group of fields ICSS architecture is shown in the below Figure 2:

ICSS shall be integrated with enterprise information systems (level 5 of enterprise informational model) via MES systems (level 4 of enterprise informational model).

Level 4.

Manufacturing Execution Systems (MES) – include Laboratory information management system (LIMS), Automatic Dispatch Control System (ADCS), Production accounting system (PAS) and Enterprise Asset Management system (EAM). This complex of modern enterprise management systems (MES) is a strategic level of intelligent information systems, which is actually “joins” ICSS system with enterprise resource planning (ERP) information systems. The versatility of complex of subsystems at this level is a unique innovation in industry of the Republic of Uzbekistan and without any exaggeration puts our country on a par with those adhering to a high-tech civilization approach.

Level 5.

Enterprise Resource Planning (ERP) information systems – include service advertising protocol (SAP), electronic document management system (EDMS), and capital funds management system.

As the level 4 and level 5 are not part of ICSS, but are designed on the basis of the above tasks as flexible as possible integrability with ICSS subsystems to create ultimately a unique intellectual system of centralized management of the enterprise.

Metrological characteristics of ICSS systems are calculated based on the below model of measurement system’s error:

Where Δ_MI - the error of measurement in real conditions of use;

Δos - the systematic component of base error of a measuring mean;

${\stackrel{\circ }{\Delta }}_{\text{o}}$ - the random component of base error of a measuring mean;

${\stackrel{\circ }{\Delta }}_{\text{oH}}$ - the random component of base error which is due to the hysteresis;

${\displaystyle \sum _{i=1}^l{\Delta }_{{\text{c}}_i}}$ - Combination of additional Δ_ci errors of measurement means, which is due to the action of the influencing factors and uninformative parameters of the input signal of measuring means;

Δ_dyn - dynamic error of measurement means which is due to the influence of the rate of change of the input signal of measuring means;

l - the number of additional errors.

Calculated results are the following:

Automated enterprise management system of Kandym GPP is designated for:

As a result of completion MES implementation project works following objectives shall be achieved:

For the achievement of above objectives following technical solutions have been chosen.

AEMS is the system that integrates the following subsystems that perform special functions associated with the individual processes of the enterprise activity and the work of individual business departments of enterprise:

Kandym GPP and Kandym group of fields AEMS architecture is shown in the below Figure 3:

In conclusion, I would like to stay for a completely unique experience of ICSS and AEMS systems integrating, with the aim of building a modern intellectual system of the centralized management of the enterprise.

The table 1 below summarizes the characteristics of the inter-system interfaces, providing flexible and reliable integration into a single system of centralized enterprise management: