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Ozenmunaigas JSC

Implementing an integrated production control system for Ozenmunaigas JSC to have accurate production data

Project Objectives

Supporting the processes related to recording and managing the entire chain of oil, gas and water production.

Project description

Between December 2015 and October 2016 ITPS configured the information systems, performed the integration testing and conducted user training. ITPS currently provides support for system users during the pilot operation of the systems.

To study the processes of production and recording product output, ITPS performed a pre-project analysis. Based on this analysis, ITPS developed an AS IS accounting model for oil, gas and water production processes, including their unique features. To correct them, ITPS proposed a number of changes to the production recording process such as changing the accounting algorithm used to measure oil output at the various wells and automatic accounting of production data using company-wide metering units.

As part of the project, ITPS implemented an integrated production recording and distribution system based on EnergyComponents (Tieto), BusinessObjects (SAP) and PI System (OSIsoft), enabling validation, personalization and consolidation of production data. This data is used to generate routine and management reports and support the decision-making process. The integrated system includes the recommended changes to the production recordting process.

The IT infrastructure of the integrated production control system is based on the Cisco UnifiedCommunications System server platform (USC), which ensures the required performance and reliability. In future, this solution will facilitate the extension and scaling of the implemented systems as required.

To enable safe communication between the IT infrastructure of the integrated production control system and domains of the Ozenmunaigas website, data security equipment was installed as part of the project. ITPS installed Cisco ASA firewalls with the FirePOWER service pack including intrusion protection and detection functionality (IPS/IDS). This solution offers an integrated approach to multi-level protection of the IT infrastructure of the integrated production control system.

The integrated production recording and distribution system performs the following functions:

Automatically collects a wide range of production data, replacing manual data input
Helps to verify and align production data
Calculates aggregated data using approved algorithms

ITPS created a basis for developing the functionality of the production recording and distribution system as part of the development of an integrated Manufacturing Execution System (MES) for the site.

Configuration of information systems

  • OSIsoft PI (1,199 tags)
  • TietoEnergyComponents (4 monthly screens, 15 daily data screens, 12 business roles, 1,400 calculation formulas for customized flows)
  • SAP BusinessObjects (5 analytical reports, 2 scheduled reports


Integration of information systems

  • Integration between the components of the enterprise exploration and production control system and the technical data base (over 135,000 entries per month)
  • Integration of PI with WinCC (23 servers) and configuration of control of data which can be edited by users as and when required
  • Integration of PI with the integrated production distribution system

 

Consulting Services

  • ITPS has developed a draft procedure for relations between the departments within the integrated production distribution system
  • ITPS has drafted 13 user and administrator manuals for working in the integrated production distribution system
  • ITPS has developed a procedure for ensuring the reliability and security of production data

Result

The Project’s key deliverable was a new accurate tool for calculating production data.

Qualitative results

  1. Improved the quality and accuracy of data by using a single automatic data system used to retrieve data from APCS
  2. Reduced the man-hours required to acquire and process field data and prepare production reports
  3. Implemented analytical reports used to monitor the quality of data, while revealing trend deviations such as dramatic changes in water content caused by input data errors.
  4. Reports in the enterprise exploration and production control system are created based on approved and uniform methods and algorithms. A unified report version is available at any management level; reports are accessible for all authorized users


Quantitative results

  1. After using the integrated production distribution system for three months, the gaps between theoretical and measured well outputs were reduced through timely detection of bottlenecks. Since the project got under way, the difference between theoretical and measured outputs has decreased by 4.6% through more accurate control of data quality in the system
  2. Out of 36 daily production data categories 27 categories are imported automatically (~1,200 data from APCS) Reduced time for
    — Creating the Company Balance Report from a few days to 1 minute
    ​— Creating the monthly operational report from a few days to 1 hour.

This report used to require the involvement of external contractors; following implementation of the integrated production distribution system it can be prepared by the Customer’s employees

 

 

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