CONSTRUCTION OF CPF COMPLEX AND

DEVELOPMENT OF KANDYM GROUP OF

FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

MES FDS(EAM)

8009-0092-00-IN-003-J15-10001-E

02 28.09.2016 ISSUED FOR APPROVAL D.S KIM N.S YOON J.H LEE

01 22.07.2016 ISSUED FOR APPROVAL D.S KIM N.S YOON J.H LEE

00 18.12.2015 ISSUED FOR APROVAL D.S KIM N.S YOON J.H LEE

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

1 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

TABLE OF CONTENTS

1. GENERAL ......................................................................................................... 3
1.1 INTRODUCTION ................................................................................................. 3
1.2 Reference Documents ......................................................................................... 3
1.3 Exclusions ........................................................................................................... 3
1.4 ABBREVIATIONS ................................................................................................ 3
2. SYSTEM OVERVIEW ....................................................................................... 5
2.1 System Architecture............................................................................................. 5
2.2 Application Architecture ....................................................................................... 6
3. FUNCTIONAL OVERVIEW ............................................................................... 7
3.1 Operational Production account of Technical object ............................................ 7
3.1.1 Functional Location (FL) .................................................................................. 7
3.1.2 Unit of Equipment (UE) .................................................................................... 8
3.1.3 Classification of technical object ...................................................................... 9
3.1.4 Spare parts management .............................................................................. 10
3.2 Operational Management of control and account of technical condition of
Equipment ...................................................................................................................... 10
3.2.1 Measuring Points and Counters ..................................................................... 10
3.2.2 Measuring Document Entry............................................................................ 11
3.3 Operational (Short-term) Planning of EMR measures ....................................... 12
3.3.1 Preventive Maintenance Planning.................................................................. 12
3.3.2 Maintenance Process .................................................................................... 13
3.3.3 Breakdown Maintenance ............................................................................... 14
3.3.4 Permits ........................................................................................................... 16
3.3.5 Maintenance Costing ..................................................................................... 17
3.4 Analysis and estimation of EMR ........................................................................ 17
3.4.1 Maintenance History ...................................................................................... 17
3.4.2 Reporting ....................................................................................................... 18
4. TRAINING REQUIREMENTS ......................................................................... 19

2 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

1. GENERAL

1.1 INTRODUCTION

Purpose of this Document

This document defines the functional requirements and functional design of the
EAM System for LUKOIL Uzbekistan operating company. This document is
valid for the duration of this project only.

Project Objectives
The objective of the EAM is to provide the following:

 Improve plant integrity, reliability and confidence level of maintenance

 Maximize plant availability by efficient and accurate data construction
 Implement and input data to establish wide cost-effective Plant Maintenance system

1.2 Reference Documents

Document ID Revision Title Remarks

8009-0092-HU01-00-430- 01 Technical Specification for
IN-SP-00001-E MES(Rev.01)

Table 1-1, Customer Supplied Document References

1.3 Exclusions
The following are not part of Honeywell scope of supply.
 Hardware and software for EAM

1.4 ABBREVIATIONS

3 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

Abbreviation
Meaning
or Acronym
COMPANY LUKOIL Uzbekistan Operating Company
CONTRACT Agreement between HEC and Honeywell
CONTRACTOR Hyundai Engineering Co. (HEC)
EAM Enterprise Asset Management (System)
PROJECT ICSS KANDYM
SITE The site where EAM is installed and operated, especially LUKOIL
Uzbekistan Operating Company
VENDOR Honeywell and its sub supplier for this project

4 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

2. SYSTEM OVERVIEW

2.1 System Architecture

The required system architecture is shown below. EAM System
implementation is part of MES.

[ Figure System Architecture ]

5 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

2.2 Application Architecture

EAM application architecture is shown below. Master data layer and plant
maintenance processing layer consist of application integrated with core ERP.

6 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

3. FUNCTIONAL OVERVIEW

3.1 Operational Production account of Technical object

The Process History Database (PHD) is identified as a suitable option after
having complete understanding of customer requirements.

3.1.1 Functional Location (FL)

Functional locations are elements of a technical structure (for example, functional units within
a system). You create functional locations hierarchically, and can also structure them based on
the following criteria:
 Functional
 Process-related
 Spatial
Each functional location is managed independently in the system, so that you can:
 Manage individual data from a maintenance perspective for the object
 Perform individual maintenance tasks for the object
 Keep a record of the maintenance tasks performed for the object

[ Examples of Functional Location ]

7 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

Company provided grouped process facilities like below:

Process Facilities to be updated

110 Well Site System

120 Cluster System
130 Gathering Station System
211 CPF Inlet Separation System
212 Low Temperature Separation System
221 Condensate Stabilization System
241 Gas Sweetening System
243 Gas Treatment Agent Regeneration System
247 Mercaptan Removal and Dehydration System
270 Sulfur Recovery System
277 Block Sulfur Storage System
313 Heat Supply System
314 Steam Supply System
322 Plant and Instrument Air System
323 Nitrogen System
331 Fire Water System
333 Potable Water System
334 Demineralized Water System
335 Cooling Water System
336 Water Injection System
338 Raw Water Pretreatment System
350 Fuel Gas System
353 Propane Refrigerant System
410 Storage and Product Loading System
424 Flare System
462 Metering Station System
484 Formation and Oily Water Treatment System
485 Waste Water Treatment System
610 Export Gas Pipeline System
623 Well Pipeline System
624 CS Pipeline System
625 GS Pipeline System
750 Water Intake System

3.1.2 Unit of Equipment (UE)

A piece of equipment is an individual object that is to be maintained independently. Each piece
of equipment is managed independently in the system, so that you can:

 Manage individual data from a maintenance perspective for the object

 Perform individual maintenance tasks for the object
8 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

 Keep a record of the maintenance tasks performed for the object

 Collect and evaluate data over a long period of time for the object.

[ Examples of Equipment Hierarchy ]

Company provided types of equipment objects like below:

 Rotating equipment;
 Control valves and instrumentation;
 On-line analysers;
 Heat exchangers and air coolers;
 Vessels subject to inspection;
 Storage tanks.

3.1.3 Classification of technical object

A classification system has the task of describing objects using characteristics, and grouping similar
objects into classes, to classify them and make them easier to find. Purpose of classification system
is to assign features in detail to a technical object that cannot be assigned to the master record by
using the fields of the SAP standard.
system.

9 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

[ Figure : Classifying a technical object ]

3.1.4 Spare parts management

A maintenance bill of material (BOM) is a complete, formally structured list of the
components
making up a technical object or an assembly. The list contains the object numbers of the
individual components together with their quantity and unit of measure. The components
can be
stock or non-stock spares or assemblies.

[ Figure : Purpose of Maintenance BOM ]

3.2 Operational Management of control and account of technical condition

of Equipment
3.2.1 Measuring Points and Counters
Measuring points are physical and/or logical locations at which a particular condition is described
10 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

- for example; the temperature of coolant in a nuclear power station after an outflow from the
pressure vessels, or the number of rotations per minute of the rotary blades of a wind-driven power
station. Measuring points
are located at technical objects.

Counters are resources that enable you to represent the wear and tear of an object or the
consumption or reduction in its useful life, for example, the mileage indicator of a motor vehicle
or the electricity consumption meter of an electrically-powered system. Counters are located at
technical objects.

[ Figure : Measurement Reading Entry ]

3.2.2 Measuring Document Entry

You enter data in the SAP System manually using the SAP user interface (SAP GUI)..
Measurement documents can also be entered remotely using Mobile Asset Management (MAM).
Process control system data is data that is created during the monitoring, control, regulation and
11 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

optimization of a technical process. You can copy this data to the SAP system using the PM-PCS
interface.

You can use various customer exits to automate your business processes and, for example,
automatically generate a malfunction report from a measurement document.

[ Figure : PM – PCS Interface ]

3.3 Operational (Short-term) Planning of EMR measures

3.3.1 Preventive Maintenance Planning

To keep downtimes and maintenance costs to a minimum, the technical systems in a company are
inspected and maintained regularly. Preventive maintenance is performed based on time, the
condition or the performance of the technical object.

12 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

[ Figure : Types of Preventive Maintenance ]

Preventive maintenance is divided into three areas:

. Time-based, that is preventive maintenance tasks are triggered after a specific period of time has
elapsed (for example, every six months).
. Performance-related, that is preventive maintenance tasks are triggered after a specific
performance level has been reached (for example, every
10,000 kms).
. Condition-based, that is preventive maintenance tasks are due when a condition is outside of a
specific value range (for example, thread depth below 15 mm or temperature higher than 85° C).

3.3.2 Maintenance Process

To keep downtimes and maintenance costs to a minimum, the technical systems in a company are
inspected and maintained regularly. Preventive maintenance is performed based on time, the
condition or the performance of the technical object.

13 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

[ Figure : Preventive Maintenance Process ]

The process of preventive maintenance contains steps for the planning and execution of regularly
recurring inspection and maintenance activities.
Step 1: The task list defines object-dependent or object-independent process steps to be performed.
Step 2: The maintenance plan is created for the object and serves to automatically generate orders
(also: notifications, service entry sheets) in accordance with particular guidelines.
Step 3: Scheduling is responsible for the regular call up of orders (notifications, service entry sheets)
as well as for recalculating planned dates.
Step 4: The maintenance order is automatically generated by the maintenance order and entered in
the order list, from where it is processed like other orders.
Step 5: The technical completion marks the order and the corresponding planned date in the
maintenance plan as finished. The date of the technical completion is used in the maintenance plan
for calculating the next planned date.

3.3.3 Breakdown Maintenance

Breakdown maintenance involves the creation and release of the maintenance order in one work step
after a malfunction has been reported (for example, by an employee in Production).
The malfunction is corrected by a maintenance work center named in the order. After the malfunction
has been corrected, the order is confirmed by the person performing the task, the maintenance
14 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

supervisor, or the maintenance planner. The order is then completed by either the supervisor or the
maintenance planner.

[ Figure : Breakdown Maintenance Process ]

15 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

3.3.4 Permits
Permits are regulations or conditions that are to be observed when performing maintenance work at
a technical object.
Examples:
 Welding permit
 Boiler inspection permit
 Restart permit
 Authorization permit for performing technical inspections

[ Figure : Technical Permit ]

16 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

3.3.5 Maintenance Costing

Maintenance cost occurred thru work order can be distributed various ways by accounting and
business needs. SAP EAM support flexible cost distribution thru CO (managerial accounting) such
as CAPEX procedure, general OPEX procedure and so on.

3.4 Analysis and estimation of EMR

3.4.1 Maintenance History

When managing technical systems, you not only want to document and support the planning of
maintenance processing, you also want long-term verification documents in the form of a
maintenance history.
The maintenance history is structured largely automatically by the PM system. The data which will
later make up the maintenance history is derived by maintaining the master data, entering and
processing maintenance notifications, scheduling maintenance plans or executing orders. The
maintenance history comprises the following sections:
 Usage history for pieces of equipment at functional locations

17 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

 Notification history and technical completion confirmation documentation

 Order history

3.4.2 Reporting
The 'Reporting' component comprises the standard analyses and flexible analyses for the Plant
Maintenance Information System. The standard and flexible analyses enable you to analyze and
evaluate data, which is written to the Plant Maintenance Information System.
The standard analyses are based on statistical data from Plant Maintenance and provide a wide range
of options for evaluating data. A wide range of functions are available as part of the standard analyses.
These functions enable you to target specific key figures and to analyze them in detail (for example,
ABC analysis, cumulative frequency curve, correlation curve, previous year comparison,
planned/actual comparison, and so on). You can specify the level of detail of information you require.
The values for each list can also be viewed graphically.
Flexible analyses allow you to group together and aggregate key figures, and to create reports easily.
This makes use of the functions in the Report Writer. Different display types enable you to vary the
layout of your reports.

18 / 19
 CONSTRUCTION OF CPF COMPLEX AND
DEVELOPMENT OF KANDYM GROUP OF
FIELDS

LUKOIL Uzbekistan
Operating Company
MES FDS(EAM)

The PMIS(Plant Maintenance Information System) is structured according to the following guidelines:
 The maintenance application data is updated online to the PMIS during its creation.
 The aim of the update is to condense the amount of data generated in the application into
informative, meaningful characteristics and key figures.
 The aggregation of application data takes place in the information structures (short: info
structures).
 Various analyses can be based on the info structures. There is a variety of standard analyses
(for example, location analysis, damage analysis, cost analysis, and so on) that are also
based on the info structures delivered in the standard system.
 You have the option of creating your own info structures and your own analyses (flexible
analyses).

4. TRAINING REQUIREMENTS
Site training to be performed by Site Supervisor. Training Material to be
provided by Honeywell. Following training programs are available for the
Customer:

Item Course No. Course Description Remarks

1. PM Overview
2. Operation Management Training
3. System Administration Training

19 / 19