Ural Oil and Gas LLP
Rozhkovskoye Field Development
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THE CONTENT OF THIS DOCUMENT ARE PROPRIETARY AND CONFIDENTIAL
ROZHKOVSKOYE FIELD DEVELOPMENT PROJECT
DIGITAL OPERATIONS ROZHKOVSKOYE FIELD
TECHNICAL SPECIFICATION (HEREINAFTER: DOR)
RZK-NSS-000-SOW-ENG-00002-00-E
23.09.2024
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or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of Ural Oil
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REVISION
E
23.09.2024
Issued for Review
Bosko
Jeremic
Srdjan Jordanovich
Jihad Sadik
D
20.08.2024
Issued for Review
Ind.Expert
Srdjan Jordanovich
Jihad Sadik
C
20.07.2024
Issued for Review
Ind.Expert
Srdjan Jordanovich
Jihad Sadik
B
20.07.2024
Issued for Interdisciplinary Review
Ind.Expert
Srdjan Jordanovich
Jihad Sadik
A
20.07.2024
Issued for Internal Review
Ind.Expert
Srdjan Jordanovich
Jihad Sadik
Rev.
Date
Issue, Modification
Prepared
Checked
Approved
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Approvals
Prepared by
Name: Bosko Jeremic
Job Title: Project Control Manager
Signed:
Date: 23.09.2024
Checked by
Name: Srdjan Jordanovich
Job Title: Engineering Manager
Signed:
Date: 23.09.2024
Approved by
Name: Jihad Sadik
Job Title: Project Manager
Signed:
Date: 23.09.2024
Digital Operations SOW
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HOLD RECORD
Where a <HOLD> status has been included within the body of the document please indicate its location by
detailing the relevant page number.
Hold Nr.
<1>
Section
Description of Hold
REVISION HISTORY
Specify significant changes from previous revisions of the document
Rev.
Date
Description of Revision
Issued for Internal Review
A
20.07.2024
Issued for Interdisciplinary Review
B
20.07.2024
Issued for Review
C
20.07.2024
Issued for Review
D
20.08.2024
Issued for Review
E
23.09.2024
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TABLE OF CONTENTS
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
PROJECT SCOPE .................................................................................................................. 6
VISUALISATION AND AUTOMATED REPORTING SYSTEM ................................... 7
INTEGRATED MAINTENANCE MANAGEMENT SYSTEM ........................................ 7
SAFE SYSTEM OF WORK AND PERMITTING .............................................................. 8
HEALTH, SAFETY AND ENVIRONMENTAL MONITORING SYSTEM ................... 9
PROCESS SAFETY MANAGEMENT AND ALARMING ............................................. 10
KEY PERFORMANCE INDICATORS OF DIGITAL OPERATIONS ROZHKOVSKOYE
................................................................................................................................................. 10
ASSET SURVEILLANCE SYSTEM .................................................................................. 11
SCALABILITY OF DOR PLATFORM ............................................................................. 12
USER MANUALS AND ENGINEERING TRAININGS .................................................. 12
PROJECT EXECUTION PLAN ......................................................................................... 12
APPENDICES ....................................................................................................................... 14
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1.0 PROJECT SCOPE
The Digital Operations of Rozhkovskoye (DOR) project includes the implementation of an
Automated Reporting System (ARS) to enhance reporting, analytics, and operational intelligence
systems and prepare the future foundation for the Digital Production Rozhkovskoye (DPR) Project
with an automated Digital Petroleum Engineering Technology and the digital twin creation.
Ural Oil & Gas company plans to execute the Stage-1 Development Project at Rozhkovskoye gas
condensate field in the Republic of Kazakhstan, commissioning 5 producing wells (U-21 single
wellhead platform and Gathering station with 4 well heads U-10, U-12, U-23, U-26), transporting
produced fluids via the trunkline towards the commercial handing over unit of the Transfer station
at the south manifold of the Zhaik Munai LLP facilities for further processing.
This Stage-1 for the Field Development has a forecast flat production rate of 1.5MMm 3/d
(53.1MMSCFD) of raw gas and 1.660m3/d (10.500 BOPD) of condensate (expected wellhead
production and the handed over fluids to ZKM facilities ~ gross volumes 19.500BOED). DOR shall
cover four main components (lighthouses) of the Rozhkovskoye field operations:
- Production and Operations System
- Maintenance Management System
- Safe System of Work and HSE Management and Reporting System
- Process Safety Management
Production and Operations component will include operations intelligence on the below described
systems which has referenced as the inside battery limits (IBL) units within the field operations
related to the real-time monitoring, production diverse reporting and green-gashouses (GHG)
modules:
- Wellheads
- Gathering Station including flowlines
- Block Valve Stations including trunkline
- Transfer Station
Maintenance Management System will provide the preconditions of Safe operations covering the
intelligent solutions for the maintenance task execution via preventive, predictive and corrective
actions as a reliability centre. Planning and scheduling shall be carried out for all service requests
initiated on short-, medium- and long-term planning aligned with short- and long-term production
priorities. The custodian will be mechanical, electrical, instrumentation and control and inspection
and testing domains. Corrosion management could be considered as well in the maintenance
package.
Safe System of Work and HSE Management System with applied electronic permit to work
system derived from standards for hot and cold permits, covering mechanical and electrical
isolation, confined space entry, excavation and trenching, working at heights and loose lifting
equipment. Health, Safety and Environmental monitoring of emissions, parameters, permits,
automatic detection of HSE non-compliance, generating HSE reports and historical data base
(Incidents, safety audits, compliance checks etc.) will be the reporting automated system.
Process Safety Management will be the system for logging, tracking, and managing safety
incidents, including root cause analysis, corrective actions, and regulatory compliance reporting.
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There should be modules for entering incidents and automatically generating reports for those whom
it may concern.
The backbone of the automated reporting and monitoring system for all 4 lighthouses will be the
ICSS – Integrated Control and Safety System.
2.0 VISUALISATION AND AUTOMATED REPORTING SYSTEM
The most important chain for achieving any digital workable success is the data accuracy collection
process. It’s the vital parameter of a data-driven bases and systems. They are usually scattered
throughout diverse company places in many different formats from significantly various data
sources.
Each of these different and compiled data sources come with their own unique management
challenges and their own complex subsystems and play an important role in an organizational
infrastructure.
Automated reporting system (ARS) will combine all those complex data sources together in one
centralized system where data will be sent, received, and transformed into a controlled environment
and stored.
Data will be collected at regular intervals predefined with agreed frequencies:
- The real time approach is used for the field smart equipment and sensors
- Daily frequency is used for parameters such as but not limited to the daily hydrocarbon
production, maintenance, safe work and process safety and alarms reporting
- Data validation will be followed by the RACI chart defined in this scope
Real-time data collection will be done using a data collection module, which requires configuration
for the Rozhkovskoye field environment. Module can collect enormous amounts of data from any
data source invulnerable to various cyber-attacks. Modules will be connected directly to
ICSS/SCADA system and/or any other operating servers in safe environment. Every data parameter
will be available on real-time dashboards and the selected ones on historical trend chart. There will
be an option of the informative data availability on the smart and portable devices.
Real-time dashboards will be available in the CCR (Central Control Rooms/Collaborative Control
Room) designed to facilitate the control and monitoring of production and operations.
Business processes will be steered by the RACI chart decision tree translated into the ARS model
and further providing focused operational excellence services. The associated business processes
determine how certain data will be captured and processed through process workflows and the RACI
matrix.
In case that Rozhkovskoye field will be throught the 3D model operable, the integration with it will
be available as well.
3.0 INTEGRATED MAINTENANCE MANAGEMENT SYSTEM
For attainable asset performance monitoring, the deployment of the predictive, preventive and
corrective maintenance solutions to provide safe operation, monitor equipment health, schedule
maintenance activities, and minimize downtime will be the key factors. Usage of condition
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monitoring sensors and analytics for proactive asset management, will be bringing the required and
proper maintenance monitoring and activities on time performing.
The next, most important elements should be included:
1. Data collection and analysis: implemented sensors and devices should collect real-time data
on equipment performance and environmental working conditions; data analytical tools
should be utilized with machine learning algorithms to analyize collected data and identify
patterns indicative of potential equipment failures
2. Conditions Monitoring: here will be analog monitoring and digitally implemented a
predictive maintenance techniques (such as vibration analysis, thermography, produced fluid
analysis, ultrasonic testing) to monitor the conditions of safety critical elements
3. Predictive Maintenance Model: Predictive maintenance models should be developed which
can forecast equipment failures based on the historical data, asset usage patterns and
performance trends; These models should be used to generate maintenance alerts or work
orders before a breakdown occurs and therefore maximize the equipment uptime and
reliability
4. Integration with analog monitoring and digital model: Integrating predictive and preventive
maintenance schedules with the digital model for streamline maintenance planning and
execution and ensuring seamless communication between maintenance teams, operations
personnel and field managers to coordinate maintenance activities effectively
5. Root Cause Analysis: Conduct the thorough root cause analysis of equipment failure to
improve predictive maintenance models and avoid recurring issues; use historical
maintenance data and failure reports to pinpoint underlying causes and implement corrective
actions to prevent future failures
6. Continuous improvement: to be established a feedback loop to continuously improve
predictive maintenance models based on performance data, maintenanc eoutcomes, and
feedback from field technicians; regularly update maintenance strategies and adapt to
changing operational conditions, technological advancements and industry best practice
4.0 SAFE SYSTEM OF WORK AND PERMITTING
When incorporating a Safe System of Work (SSOW) and permitting processes into a digital solution
for Rozhkovskoye field development, it's essential to ensure that safety protocols are robust,
compliance is maintained, and operational efficiency is optimized. Here are some key considerations
for integrating SSOW and permitting into a digital solution:
- Digital permitting system: a digital permitting system will be implemented and will allow
for the electronic issuance, tracking, and management of permits for various work activities,
such as hot work, confined space entry, and equipment maintenance. It will ensure that the
permitting system follows predefined workflows, includes necessary approvals, and
provides real-time visibility into permit statuses
- Risk Assessment and Mitigation: Integrate digital tools for conducting risk assessments,
hazard identification, and control measures in alignment with the SSOW should be
implemented. Use interactive risk assessment software to evaluate potential risks associated
with specific tasks and ensure adequate precautions are in place to mitigate these risks
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Authorization and compliance check: Digital authorization process will be incorporated
which will link permit approvals to required qualifications, training certifications and
competence assessments. If possible, automated compliance checks should be implemented
for verification of all prerequisites for executing work activities are met before permits are
issued.
Real-time monitoring and reporting: a digital platform will be utilized for real-time
monitoring of work activities, permit conditions and compliance with safety regulations,
generating automated reports and dashboard to track permit utilization, trends in incidents
and overall Rozhkovskoye field safety performance
Incident Management and Lessons Learned: tools for incident reporting investigation, and
corrective action management will be implemented, to capture and address safety incidents
promptly. Facilitation and sharing of lessons learned from incidents to improve SSOW
practices, enhance safety awareness and prevent future occurrences should be achieved.
5.0 HEALTH, SAFETY AND ENVIRONMENTAL MONITORING SYSTEM
To develop a comprehensive Health, Safety, and Environmental (HSE) monitoring system in digital
form for Rozhkovskoye field operations, will be considered the following components:
- Real-Time Data Collection: Implement devices, sensors, and monitoring tools to collect realtime data on environmental conditions, emissions, equipment status, and worker safety
indicators and integrate data acquisition systems to aggregate information from various
sources and ensure data accuracy.
- Dashboard and Visualization tools: an interactive dashboard and visualization tool to display
key HSE metrics, performance indicators and compliance status will be developed.
Stakeholders should have real-time visibility into HSE data and trends for informed decision
making.
- Risk Assessment and Management: the created digital platforms will be utilized for
conducting risk assessments, hazard identification, and risk mitigation strategies, as well as
for the risk management tools implementation (prioritization and track mitigation actions to
reduce HSE-related risks)
- Incident reporting and Investigation: it will be integrated a digital incident reporting system
for employees to report safety incidents, near misses and hazards promptly with automated
incidents workflows for investigation, root-cause analysis, corrective actions and follow-up
measures.
- Environmental monitoring: sensors and environmental monitoring technologies will be used
to track air quality, water quality, noise levels, and other environmental parameters.
Environmental data will be analysed to assess potential impacts, identify trends, and
implement mitigation measures.
- Emergency Response Planning: digital emergency response plans, procedures, and
communication protocols for HSE incidents will be developed. Scenario-based drills and
simulations using digital tools to test emergency preparedness and response effectiveness
will be conducted.
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6.0 PROCESS SAFETY MANAGEMENT AND ALARMING
When implementing Process Safety Management (PSM) and alarming in digital form in the
Rozhkovskoye field operations, it's crucial to prioritize the safety of personnel, assets, and the
environment. Here are key elements to consider:
- PSM documentation management: PSM documentation, including process hazard analysis,
operating procedures, mechanical integrity records and management of change procedures
will be digitized (centralized within a digital platform for easy access, version control and
audit tracking)
- Safety Instrument Systems Integration: Safety Instrumented Systems such as Emergency
Shut Down (ESD), fire and gas detection systems (FGD) and pressure relief devices will be
connected to a centralized digital control system. The alarm management software to
configure, monitor and prioritize alarms based on risk level and criticality will be
implemented.
- Risk Assessment tools: Digital risk assessment tools will be utilized in order to identify,
evaluate and mitigate process safety risks, including process hazards, equipment failures and
human factor. Risk assessment data will be integrated with alarming systems to trigger
appropriate responses in ESD.
- Alarm Rationalization and Management: Alarm rationalization exercise should be
implemented to review and optimize alarm setpoints, priorities and response procedures.
Here will be implemented alarm management software to reduce alarm floods and
minimizing alarm fatigue for improved operator’s response effectiveness.
- Incident reporting and analysis: A digital incident reporting system will be established to log
process safety incidents, near misses and abnormal situations, as the basis to investigate root
causes, track corrective actions and prevent recurrence of incidents.
- Performance monitoring and reporting: Digital dashboard like in the previous elements
should be developed for real-time monitoring, generating safety performance reports and
KPI’s to assess PSM effectiveness and compliance with safety standards.
7.0 KEY PERFORMANCE INDICATORS OF DIGITAL OPERATIONS
ROZHKOVSKOYE
Key Performance Indicators (KPIs) play a vital role in measuring the effectiveness and efficiency
of digital operations in any industry, including oil and gas field development. Here are only essential
KPIs that can help monitor the success of Rozhkovskoye digital operations:
1. Automated Reporting System
This will significantly streamline data collection, analysis, and reporting processes. Data integration
system will be capable of aggregating diverse sources (sensors, ICSS/SCADA, wellhead
production, maintenance records, HSE and PSM data base) and standardized reporting templates
for various stakeholder’s regulatory bodies and internal teams will ensure consistency and clarity.
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2. Operational efficiency
Downtime reduction and Production yield with measured percentages of unplanned downtime of
SCE and tracking the efficiency of production processes and usable outputs will significantly
improve overall system performances.
3. Cost Management
The cost evaluation of production per unit volume of produced fluids and maintenance cost ratio
(monitoring the ratio of maintenance costs to overall operational expenses) will be real-time
monitored and basis for improvements.
4. Safety Performance
Total Recordable Incident Rate (TRIR) measurement of the total number of work-related incidents
per 100 employees and Lost Time Injury (LTI) with tracking the number of lost time injuries per
million hours worked.
5. Environmental Impact
Carbon Emissions Intensity with measurement the amount of carbon emissions per unit of
production and water usage efficiency in operations
6. Technology Adoption
Digitization successfulness implementation will trigger the next step toward digital production
implementation in the Rozhkovskoye field. Maturity index will help to assess the level of this digital
transformation within the organization.
7. Workforce Productivity
This could be the measure of the output per hour worked by employees. The training effectiveness
by tracking the impact of training programs on employee performance and adoption of digital tools
will be optionally analysed.
8.0 ASSET SURVEILLANCE SYSTEM
Developing an Asset Surveillance System as part of the digital operations process in Rozhkovskoye
field is essential for monitoring, managing, and optimizing its performance and critical parts. The
most important asset’s benefits will be:
- Enhanced field reliability
- Cost Optimization
- Safe Operations
- Performance Optimization and
- Decision Support.
Here are key components and benefits which should be considered when implementing an Asset
Surveillance System:
1. Remote Monitoring Sensors: Install Internet of Things (IoT) sensors and devices on key
components of the production and operations systems such as pumps, valves, compressors,
pipelines, and tanks to collect real-time data on operating conditions, performance metrics,
and environmental parameters. This will be covered by a future contractor scope.
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2. Integration with ICSS/SCADA Systems: Integrate the Asset Surveillance System with
Supervisory Control and Data Acquisition (SCADA) systems to centralize monitoring,
control, and data acquisition functionalities for seamless asset management.
3. Predictive Maintenance Tools: Utilize predictive maintenance technologies such as vibration
analysis, thermal imaging, oil analysis, and equipment monitoring algorithms to detect early
signs of asset degradation, anticipate failures, and optimize maintenance schedules.
4. Data Analytics Platforms: Implement data analytics platforms with machine learning
algorithms and Artificial Intelligence capabilities to analyse asset performance trends,
predict potential issues, and generate actionable insights for proactive decision-making.
5. Alarm Management System: Establish an alarm management system that generates alerts
for abnormal conditions, equipment failures, safety hazards, or performance deviations to
enable prompt response and intervention by operators.
6. Future Digital TWIN solution: Develop digital TWIN of critical equipment to create a virtual
replica, which will be mirroring real-world behaviour for simulation of different scenarios,
without operations disruption.
9.0 SCALABILITY OF DOR PLATFORM
Rozhkovskoye field management intend to expand in the stage-2 digitalization towards the digital
twin solution for the production optimization, Digital Production Rozhkovskoye (DPR) project. It
is crucial that the Digital Operations Rozhkovskoye Project (DOR) which is the subject of this scope
of work will successfully be implemented with all elements as the basis for the DPR and final digital
twin based on the workflow software artificial intelligence.
10.0 USER MANUALS AND ENGINEERING TRAININGS
As part of digital transformation change management, internal skills need to be upscaled on level
that enables efficient governance of DOR platform for the Rozhkovskoye asset team. Bidders need
to provide training agenda for Automatic Reporting System and all components within DOR
platform with associated training materials and cost. As the part of this scope, licenses will be
procured and during the pilot first year running will be integrated part of the project, while the
licenses after the project handing over will be the operational expenditure of Rozhkovskoye field.
11.0 PROJECT EXECUTION PLAN
Note: Project execution plan is given tentatively. A Bidder should develop and propose schedule
adjustments aimed to improve project efficiency, if justified and providing enough time for all
necessary project activities, including approvals, both on Bidder and Customers side.
Phase 1: It refers to the initial delivery and aims to provide Design and acquire of Hardware &
Cloud software (OS/VS) licenses for ARS Project. There should be certain deliverables in this part
like:
- Engineering with textual, tabular and graphical documents
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-
Procurement of Hardware and Software licenses: preparation of material acquisition,
tendering of the Automatic Reporting System (ARS) server(s), bid evaluation and purchase
request(s), contracts with vendor(s) and logistics
- ARS server supply, hardware licenses and the factory acceptance test, installation,
commissioning and start-up
Phase 2: the phase 2 is going to be the continuation of the phase 1 towards the digital
goals/lighthouses as described in this scope of work. Several work packages will be under
implementations with the main functional element’s definition (Daily Operations reporting and
Accounting, Daily Maintenance reporting, Governmental reporting, SSOW and PSM reporting):
- Development and implementation of Manual input application
- Data extraction from diverse sources
- Data transformation (compiling, converting, reforming, cleansing)
- Data loading (extracted and transformed data loading into the loading data sheet)
- Data base setup, optimization and further running
- Daily operation reporting (production, real-time data) modules implementation
- Daily maintenance reporting (preventive, predictive, corrective, work orders) modules
implementation
- Daily Safe System of work module loading and implementing (hot and cold digital
permitting, risk assessments etc)
- Daily Process Safety Management (safety instrumented systems, alarms and notifications,
risk assessments etc)
- Environmental reporting and emission accounting including governmental reporting system
Phase 3: In this phase, the ARS software will be entirely implemented by establishing a process to
take the ARS from planning and development to the final production stage. Phase 3 will be the
finalization of the technical work and handing over project to the UOG with all capabilities:
- User adoption and acceptance test
- Education and Training
- Trial period
Phase 4: Commissioning and start-up (Site Acceptance Test)
Commissioning will include the Server system with all hardware and software, as well as
application for reporting, analytic and OI of the Rozhkovskoye Field
A future bidder could intent to utilize as much as possible “plug and play” equipment. Due
to that reason, FAT (Factory Acceptance Test) could be limited to a bidder provided
information.
After successfully executed commissioning procedures, a future bidder will perform initial
start-up of equipment in scope.
During the commissioning period, a future bidder will provide onsite one week training for
the UOG operation personnel.
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12.0 APPENDICES
1. RZK-NSS-CMG-PFD-ENG-00001-01-E; Process Flow Diagrams - Wells & Gathering Station
2. RZK-NSS-CMG-PFD-ENG-00001-02-E; Process Flow Diagrams - Transfer Station
3. RZK-NSS-CMG-DPP-ENG-00003-01-С; Plot Plan 1 of 3
4. RZK-NSS-CMG-DPP-ENG-00003-02-С; Plot Plan 2 of 3
5. RZK-NSS-CMG-DPP-ENG-00003-03-С; Plot Plan 3 of 3
6. RZK-NSS-CMG-DBD-ELE-70001-00_E; Block Diagram - Overhead Lines
7. RZK-NSS-CMG-DBD-TEL-40001-00-0; Block Diagram - Communication & PAGA
8. RZK-NSS-CMG-DBD-TEL-40002-00-0; Block Diagram - ACS, CCTV, Perimetry
9. RZK-NSS-CMG-DRG-ENG-00001-00-E; Block Diagram - Utility Flow Diagram
10. RZK-NSS-KMGA-CSA-ENG-00001-00-0; ICSS Architecture
11. RZK-NSS-CMG-I_Q-INS-01001-00-C_EN_RU; IO LIST Transfer Station
12. RZK-NSS-CMG-I_Q-INS-05001-00-С_EN_RU; IO List - Valve Station VS1
13. RZK-NSS-CMG-I_Q-INS-06001-00-C_EN_RU; IO List - Valve Station VS2
14. RZK-NSS-CMG-I_Q-INS-07001-00-C_EN_RU; IO List - Valve Station VS3
15. RZK-NSS-CMG-I_Q-INS-08001-00-C_EN_RU; IO List - Valve Station VS4
16. RZK-NSS-CMG-I_Q-INS-09001-00-C_EN_RU; IO List - Valve Station VS5
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