Angarsk Petrochemical Company (ANHK) (PI System)

The systems of production supervision and accounting of Angarsk Petrochemical Company based on PI System

Introduction

Angarsk Petrochemical Company (JSC ANHK), the largest enterprise of Eastern Siberia for oil refining, oil products output and products of petrochemistry, in 2015 will celebrate the 70-year anniversary. Since 2007 it is subsidiary of the oil company JSC Rosneft. Now oil refining volume in it exceeds 10 million t. in a year, and depth of processing is 72.16%. The range of products makes more than 200 names in three directions – oil products, petrochemistry and oils. The enterprise is certified according to four international standards. The oil processing and chemical plants, the plant of oils, production of fuels, commodity and raw production are a part of ANHK. Since 2007 step by step at plant the complex of the systems of the automated production accounting (SPU) which covers all productive activity of JSC ANHK is created and implemented.

The following information systems entered a complex of the SPU:

• - technological monitoring system (TMS);
• - dispatching system (DS);
• - laboratory information management system (LIMS);
• - automated system of calculation of a material balance (ASCMB);
• - automated diagnostic system (ADS).

Project implementation of the SPU was directed to receiving by the management ANHK of the broad picture of all production processes, operation of process units, movements of oil products, data of a material balance; and already with arrival of management company JSC Rosneft the project purchased visible borders and with the assistance of the supplier of PI System, OSIsoft company, the new vector of development was set.

Let's consider the systems of a complex of the SPU which are based on infrastructure of data of PI System.

Technological Monitoring System (TMS)

Information basis for the subsequent stages of creation of the SPU was the technological monitoring system for which program tools selected the PI System software product of OSIsoft company. After formation of technical requirements by the company to a system the open tender based on which the contractor – IndaSoft LLC which at the same time delivered software and performed engineering works on creation of STM is selected was held. The complex of engineering works provided carrying out preproject inspection, namely: inspection of the existing PCS systems and their data exchange protocols with external systems, determination of structure and forms of the output data for users and a set of the user reporting. Based on the conducted examination the report was prepared, being based on its results contract organization the private technical specifications, and then and a techno detail design was developed. The order on JSC ANHK created the working group on implementation of STM under the leadership of the associate director technical on IT – the head of department of IT of JSC ANHK. Internal orders on divisions of ANHK designated responsible persons for providing initial data and other information required for system implementation. At the meetings held by the working group such questions as filling of questionnaires, providing operator screens of installations to the contractor of printskrin, preparation of the draft agreement on the unified name of tags and the graphical interface, determination of lists of client stations on which testing and the statement of standard symbolic circuits and reports on installations and reservoir parks, approval of connection of the equipment of the PCS of the installations accepted for carrying out trial operation to the STM server, determination of lists of users and an operation mode of administrators and also many other questions will be held were considered.

Originally, in 2007, PI Server on 25 thousand tags was unrolled, both the client software and interfaces is purchased server. A little later test PI Server for testing of work of symbolic circuits before their output in commercial operation is purchased.

The technological monitoring system is constructed using the database of real time using which the following problems are successfully solved:

• - automatic data acquisition of real time (values of the measured values of technology processes) from installations and reservoir parks by means of interfaces to the functioning PCSs;
• - creation of the uniform archive providing long-term reliable storage of the continuous and retrospective data (on hard drives of the server);
• - processing and submission of collected data on symbolic circuits to users of ANHK.

When developing STM technical solutions on information exchange with the automation systems of different producers which are available at plant were fulfilled: Honeywell, Yokogawa, Siemens, Saab, Tecon.

STM was developed and implemented in trial operation during the period from 2007 to 2008, and is transferred to commercial operation in June, 2009, after working off of all notes and recommendations, conducting complex testings, preparation of a packet of accompanying program and operational documentation, receiving all necessary approvals from heads and chief specialists of services of JSC ANHK. In particular, security experts approved the data protection mechanism in STM which was previously approved by the RSU main producers.

The implemented technological monitoring system provides:

• - condition monitoring of technology production processes in real time;
• - horizontal integration of different PCSs based on a single information platform of real time what convenient access to control and to credentials of work of production of different services is result of: technology, metrological, production, laboratory, etc.;
• - increase in depth of job analysis of production due to use of the stored historical data, creations of the structured hierarchies of data, the developed data visualization;
• - the centralized administration of STM and data protection.

Today the number of an automated workplace of users of STM makes more than 250 pieces. Considering changes in personnel structure which happened in different services ANHK since 2007 (from the moment of the beginning of implementation of STM), in April, 2013 fact-finding lectures on work with functionality of STM were organized and given. The purpose of these lectures was training of new employees and a reminder of the principles of work with a system and features of its new functionality for the experienced, long ago working specialists.

Now STM is implemented on all productions. Expansion of application is performed constantly according to requests of the plants, services and the test center (the test center integrates all laboratories of JSC ANHK), completion existing and development of new symbolic circuits is performed by specialists of ANHK instrumentation and automated control systems workshop who underwent the corresponding training. So, for example, addition of the section of STM "Gas contamination" is implemented now.

System of scheduling

The second system of a complex of the SPU is the dispatching system (DS) which was implemented into the period from 2008 to 2012. It is constructed based on a technological monitoring system and supplements it regarding obtaining technology data of manual entry from the objects which are not equipped with the PCS and also regarding data acquisition on movement of oil and oil products on production.

Implementation of SD began with inspection of organizational and production structure of ANHK, the principles of the organization of management, the existing document flow at supervisory control, interactions of divisions, coordination of actions of operators and managers, studying of the information systems used on JSC ANHK. Examination of the plants, additional in relation to STM, as the sources containing information on the used PCSs, number of parameters of manual and automatic entry, existence of tags with the ORS-addresses was conducted. The calculations executed by operation personnel were analyzed. On the basis of the completed questionnaires schemes of material flows for use in the project documentation were created. Private technical specifications and the engineering design of a system were result of these works.

Dispatching system combines work of two main automated workplaces of development of IndaSoft LLC on the platform of PI System:

• - the first automated workplace of manual entry of process parameters (I-MLS) on fabrication systems and fixing in the automated workplace of the passport data used for calculation of weight;
• - the second automated workplace of accounting of the movement of oil (I-OMS) which processes data on reservoir parks. I-OMS-Client allows to make calculation of mass of oil product in the reservoir (and its errors), using the built-in software module of calculation of weight and volume of oil/oil product corresponding to the measurement techniques entered by JSC Rosneft in 2011. All information on the movement of oil comes to a data archive of real time of PI Server. After preprocessing a part of data is transferred as input parameters to the server of calculations of PI ACE where they are processed by different algorithms for receiving settlement technology indicators. The calculated measure values register in PI Server.

Thus, dispatching system provides:

• - registration of transactions of pumping of oil and oil products;
• - calculation of mass of oil and oil products for the approved algorithms;
• - automatic formation of the reporting under work of units and the movement of products in reservoir parks (replaceable the official report, regime sheets, accumulative balances of parks, reports on processing on installation);
• - providing to divisions of JSC ANHK of information on the movement of raw materials, semi-finished products and finished goods.

Dispatching system is implemented on all productions of the company. It was put into operation by queues and today contains more than 80 industrial operated objects and operator. During implementation a number far off of the located objects was connected to the computer network, it purchased and set in operator computing and office equipment, jobs are configured, training of technology personnel operator on work with a system is provided. One of the stimulating factors which helped to motivate and interest technology personnel in work with a new system was the possibility of tracking of transactions of the movement of oil products not only within the walls of operator, but also from other jobs: chiefs of installations, parks, management of technology workshops.

Eventually different completions of a system according to requirements of both heads of JSC ANHK, and departments of JSC Rosneft were required. So, for example, during the period from 2011 to 2012 completion of SD for ensuring fulfillment of requirements of JSC Rosneft on the Project "Operativnoye upravleniye raspredeleniyem resursov (OURR") was performed. Within completion of OURR the functionality of SD on automatic formation of the production schedule for a five-day week on the basis of the monthly production schedule is implemented. Actually, according to the volume plan calculated by the PIMS program on each product load its monthly plan into PI System and break it in proportion into six five-day weeks. The received schedule is loaded into functionality of OURR, and further the planner works with it, adjusts it, if necessary, for transfer to JSC Rosneft. The production schedule and information on the actual production volume goes to Department of production planning, deliveries and logistics of JSC Rosneft. For managers TSP and Refinery the completion of SD which provided a possibility of formation and receiving from dispatching system of electronic replaceable and daily official reports and magazines is executed, after that a number of hand-written magazines in dispatching offices of TSP and Refinery was cancelled.

Dispatching system exchanges data adjacent to the following systems:

1. 1) automated information system of accounting and control of the movement of oil products in commodity distribution network of the company (AIS TPS). This system works at Oracle DBMS. It is intended for accounting of existence of products, order placement and orders on shipment of products, operational planning of shipment across Russia and for export, document creations of a holiday on railway, motor transport, the pipeline, the cost accounting on transportation;
2. 2) laboratory information management system (LIMS). It is implemented on a software platform of LabWare LIMS and implemented in all laboratories of the Test center JSC ANHK. A system automates production processes in laboratories of the test center, will organize storage of analysis results, develops documentation on quality of semi-finished products and finished goods;
3. 3) management system of the station of mixing of TSP gasolines. It consists of the continuous analyzer of Yokogawa company and the corresponding software package of process control of mixing in pipelines. This system allowed to make mixing with the minimum costs, to minimize the repeated adjusting mixing, to lower the wastage rate.

Information exchange of SD with external systems is performed by the following specific communications:

• - from LIMS data of laboratory analyses of the test center come to SD (in particular, density of oil products which is used for calculation of mass of oil products in SD);
• - from SD in the AIS TPS information on the mass of oil products is transferred in reservoirs and information on transactions of movement of oil products. Movement in this case is meant not only as operations on transfers, but also data on indicators of contents of reservoirs: weight, temperature, level, oil product density. Besides, information on actual production of products and on the scheduled plan of production on five-day weeks is transferred to the AIS TPS every day from SD (according to requirements of the OURR above-stated project). From the AIS TPS data on quality certificates and information on volume of the shipped products come to SD using the PI RDBMS interface. Also receives data on mixing of products and information and on a status of the automated latches of SD from a management system of the station of mixing of TSP gasolines.

Automated system of calculation of a material balance

The progressive tense was not possible to start implementation of the automated system of calculation of a material balance (ASCMB) because of difficult process of approval of elements of the project documentation both in JSC ANHK, and in specialized department of JSC Rosneft. But in 2010 technical requirements were approved, and the project documentation is developed and approved further. In 2012 implementation of ASRMB began. Automation objects are settlement processes of a daily and monthly material balance as separate divisions (TSP, Refinery, the plant of oils and chemical. plant), and all JSC ANHK in general. Settlement process of a daily material balance is intended for obtaining the values of mass measurements approved within balance sheet model on the basis of data of primary production accounting. Main objectives and problems of system implementation are reduction of temporary costs of formation of a material balance, quality improvement and reliability of calculation of balance, automatic formation of reporting documents, increase in objectivity of data of a material balance, identification of inexact and faulty measuring instruments of expenses, reduction of influence of a human factor by calculations. Functionally a system is under construction based on information of dispatching system. Information streams at data preparation for balancing contain the evidences of primary measurements given to laboratory and metrology, given primary production accounting of mass of the moved flows and a remaining balance in reservoirs (fig. 2).

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Calculation of a material balance is made for every separate day. Besides, calculation of accumulative balance since the beginning of month on reporting day is made (not including closing of month). Calculation of a monthly balance considers the available accumulative balance: it is calculated since the beginning of month on the last date.

TSP acted as pilot section of implementation of a matbalans, exactly there until implementation of ASRMB the automated workplace "Accounting of the Movement — an Enhanced Mode for TSP" on the I-OMS EX software product which represented a certain symbiosis of accounting of the movement of oil products and a matbalans was set. Based on work in the test mode of this automated workplace then adjustment and completion of model of balance was made for ASRMB.

The first stage of implementation of ASRMB covered TSP and Refinery. The order on JSC ANHK created the working group on implementation under the leadership of the associate director technical on production with the participation of which meetings on system implementation, corrections of actions of participants of process of the automated daily and monthly data of balance of TSP and Refinery were held. Technologists of TSP, economists of TSP and Refinery, production department and economic planning management were involved in process. If to speak in general about the specialists involved in process, then the circle of these participants was wider: there chiefs of installations and parks, responsible for the organization of operability of the PCS systems and servers of data transmission, the staff of instrumentation and automated control systems workshop and metrological laboratory, personnel of the test center and Management of logistic providing entered. The role of each of participants of process is stated in the corresponding Regulations of formation of a daily material balance in ASRMB.

It should be noted that the order of approval of data when balancing begins with search of gross errors. Technically it is implemented by the special tests which are "sewn up" in I-DRMS software. By search of gross errors at first the preliminary analysis during which the fact of their existence in the scheme is elicited is made and "suspicious" measurements are specified. Then by special tests on "suspicious" measurements of an error are localized.

In May, 2014 the first stage of ASRMB on objects of TSP and Refinery was put into commercial operation. Very first process joins technologists of TSP. Work daily begins with the fact that technologists of TSP create the daily period in a system, load data of operators, analyze information on in bulk, to a remaining balance, existence of imbalances and their reasons, adjust gross errors. If the technologist cannot independently define a cause of error, he contacts operators of reservoir parks, process systems and/or service instrumentation and automated control systems to define the reason: fault of the device, admission of data entry or error of data. Further economists get to work: they check and process data, if necessary adjust errors contacting operators. The data processed by economists daily automatically are transferred to the Operational daily report of JSC ANHK. On the basis of data of accumulative balance on the 1st day of every month the production reporting is prepared: accounting of the movement of oil and oil products, mixing accounting, report on processing on installations. According to accumulative balance acts of removal of a natural remaining balance automatically form.

Implementation of implementation of ASRMB along with such actions as upgrade of KIP devices, improvement of technology schemes, equipping of reservoirs with oil products aluminum pontoons, equipment of reservoir parks the closed schemes of drainage of reservoirs, allows to lower the wastage rate.

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Now on JSC ANHK started implementation of the second queue of ASRMB at the plant of oils and chemical plant.

Automated diagnostic system

After a while after commissioning of STM and SD, specialists of escort service and administrators faced complexity of timely identification of such problems as lack of data on technology symbolic circuits of STM, including because of loss of communication with a remote measuring instrument, lack of data in reports, admissions of data entry by operators (or untimely input). Search, diagnostics and the analysis of this or that problem and also its elimination could occupy rather progressive tense during which a system or its separate components were disabled. A chain of phone calls to specialists of the PCS, administrators of separate components, search of responsible specialists – all this slowed down process. For prevention of failures in system operation, minimization of their effects, condition monitoring of subsystems and the infrastructure providing working capacity, the supplier of PI System suggested to use products: PI Syslog Interface and I-MAD/PI (so-called a monitoradministrator) using which to develop and implement the system of self-diagnostics of the SPU. This system was the developed automated system of diagnostics (GARDEN) with the following functionality: collecting and comparison of data on the history of work of components and services; the analysis of possible origins of failures in operation of technical means and the equipment at data transmission; determination of the reasons of admissions of data entry by operators. SAD prepares the detailed reporting under all violations in work of the systems of the SPU. Specialists of maintenance together with competent specialists of the customer (JSC ANHK) determined keyword parameters for control, rational data visualization, prepared and approved technical requirements to the SAD system then the software tool of diagnosing and signaling of violations was developed and implemented. A uniform point of collection of information about operability of the systems of the SPU and about their faults is the administrator accompanying a system who quickly notifies the relevant employees, takes necessary measures for compensation of violations. Work of SAD improves coordination of actions after maintenance of the systems of the SPU.

Conclusion

Speaking about difficulties which it was necessary to face during implementation of subsystems of the SPU, it is necessary to remind of previously conducted examination which revealed among other things need of upgrade of objects and retrofitting of some points new metering devices [1, 2]. It was required to connect to the computer network a number far off of the located objects, to make changes to the regulating documents and techniques of calculations. One of important tasks was preparation and training of a team of specialists for support of the SPU. Began with the consulting seminars training to programming essentials in PI System. Further accumulated experience, participating in joint work with specialists of contract organization: in completions of subsystems, in implementation of additional functionalities. With patience and attention treated personnel training at the plants, carried out retraining, on a permanent basis rendered consultations that is considered by the agreement on maintenance of a system.

Considering a question of acquisition of software PI System it is possible to note that all procurement procedures were undergone within the regulating documents of JSC ANHK and JSC Rosneft. By software it was purchased in process of implementation of each of systems. 25 thousand tags were originally purchased, expansions to 40 and 60 thousand were made further, in 2012 expansion to 100 thousand tags is made, at the moment it is enough and there is a necessary stock.

Technical support of software of PI System is performed by their producers: OSISoft and IndaSoft LLC.

From features of use of software it is possible to select the following aspects:

• - the server of engineering calculations of JSC ANHK is used not only as the calculator; the module software with techniques of accomplishment of measurements of volume and mass of oil is built in it;
• - borders of the software tool PI AF are expanded that allowed to use it as a complex of mathematical modeling in a problem of automatic formation of the production schedule in dispatching system;
• - for the symbolic circuits which are again developed by specialists of ANHK instrumentation and automated control systems workshop in STM software of test PI Server is used; on which ambassador of check of a symbolic circuit are brought to the industrial server.

Maintenance and administration of the systems of the SPU is performed by service organization of Rosneft, RN-Inform LLC. For JSC ANHK this Irkutsk regional production government of the Krasnoyarsk branch RN-Inform LLC which specialists work directly in Angarsk.

In plans at JSC ANHK expansion of production borders of the SPU:

• - in STM connection of objects which equipment of RSU is provided from 2012 to 2020 by the program of upgrade of objects of JSC ANHK and transfer of management of TP on RSU is planned;
• - in SD it is going to implement requirements of Management of economic safety for protection of a system with protection level not lower than 1D on classification of FSTEC; work options of implementation of functionality of electronic signatures of official reports; implement interface to a single system of vibration diagnostics of the equipment of JSC ANHK; automate process of issue and control of execution of dispatching instructions of workshop of operation of intershop communications.

For control over the implementation of regulations of the technology mode of installations it is going to develop and implement a monitoring system of deviations of values of the measured and analyzed values from the set regulations of the technology mode of production facilities as now process of variance analysis from regulations of the technology mode by department of the chief technologist of JSC ANHK is not automated and made monthly according to collected regime sheets of objects. The planned system will allow to see once all exits for regulation in STM and in SD. A system will allow users to obtain available and comprehensive information about a deviation of parameters of the proceeding TP in a report form, to save archive of accumulated information about deviations of process parameters with providing the subsequent analytical data processing to an opportunity. Today technical requirements to the Monitoring system of deviations of parameters from regulations of the technology mode are developed and approved, procurement procedures at the choice of the contractor are carried out, implementation is planned until the end of 2015.

The Energy Efficiency Control System (EECS) planned to development, the main sources of data for which will be STM and automated systems of technical electricity metering and scheduling of power supply (ASTUE/ASDUE) which are available on JSC ANHK, is interesting to development of the SPU by the direction. Creation of SKE is provided by the program of energy saving of JSC Rosneft Oil Company.

In general the project of the SPU on JSC ANHK is perspective, ASOUP is included by JSC Rosneft in the program of creation and its successful implementation will provide to all personnel of production services of the company tools in their daily work for operational production management at the modern level.

M.V. Zamyatin, V.Yu. Manturov, E.I. Chistova (JSC ANHK)