Condition Based MaintenanceCondition Based Maintenancekonferanse.maintech.no/fileshare/filarkivroot/Konferanse/2010... · Condition Based MaintenanceCondition Based Maintenance

Condition Based MaintenanceCondition Based Maintenance

An Aker Solutions initiative within Integrity Management services.

Agenda

■ Vision■ The challenge■ The challenge■ The alliance■ What is needed to realise CBM

● Skills● Experience

S■ Solution example■ Support structure and organisation

Proof of concept example■ Proof of concept example

© 2008 Aker Solutions part of AkerSlide 2

Vision

■ The vision of the Alliance is to provide a global service, utilising the p g , gcomplementary strengths of our individual companies and combining them into unmatched offerings of systems and services for asset management in the oil and gas industry


The ChallengeThe Challenge

Condition Monitoring - Condition Based Maintenance

Due to instrumentation and high bandwidth available, new O&G g ,installations offer new opportunities for asset care and maintenance.

7 – 10% reduction per year ?

%Preventive maintenance

C

x%

y%

Corrective maintenance

C diti b d i t

z%

Condition based maintenance

2010 2011 2012

How do you optimise your maintenance programs?


Improvement initiatives of oil & gas companiesCondition based maintenance (CBM)Condition based maintenance (CBM)

Major oil & gas companies world wide are CBM concepts for critical systems & equipment Condition monitoring portalsystems & equipment o Remote condition monitoring (CM) of critical systems and

equipmento Proactive instead of preventive maintenance processes

The companies typically have been Typical technology stackCondition monitoring & analysis

Condition monitoring portal(Dashboard)

TCI calculator

pris

e

The companies typically have been doing this in two stepso First facility or field specific CM

centres, processes & solutions o Then corporate CM centers and

Step 2Step 2yp gyg y

applications

Information Integration Framework (based on open

industry standards like ISO15926

Ent

erp

Historian(s)

Equipmenty

Historian(s)

o Then corporate CM centers and common CM processes and solutions

The leading companies now are l i t t k b th t

Data historian(s)

industry standards like ISO15926 & Open O&M)

SNetworks

Control system(DCS)

Equipment monitoring systemsFa

cilit

y

Networks

Control system(DCS)


cilit

yplanning to take both steps simultaneouslyo To standardize and scale its CM

processes and solutions Step 1Step 1

Control system(DCS)


cilit

y

NetworksSensorsSensorso To reduce implementation time and

realize economies of scaleo To use its CM expertise efficiently

across facilities Normally not part of CBM initiatives as such

SensorsNetworks


initiatives as such

Improvement initiatives of other companiesSignficant business benefits

Improvement potential

35

4035%

25

30

emen

t

15

20

% im

prov

e

15%

5

10

%

50/50 split CBM & 50/50 split CBM & production production

optimization optimization

10% 15%

0Increased production

Reduced costs

3%


Source: OLF, 2008

production

Condition Based Maintenance is more than condition monitoring

Look at the total picture

People Interaction■ People ● Attitude and behavior towards CBM● Communication – onshore/offshore/disciplines● Knowledge Management

Interaction between;

■ Process● Integrate onshore and site staff in CBM● Clear defined CBM KPI's● Enhance Roles and Responsibility

People Process

● PM review - get rid of unnecessary PMs

■ Technology● CM tools easily gives status of plant and equipment

■ Enterprise network v/ Technical networkTechnology

p● Many CM/PM tools - integrate● Common CBM portal


The AllianceThe Alliance

A partnership to solve an industry challenge


The alliance

• Operational philosophy• Knowledge transfer

Customers

Knowledge transfer

Success

•Decision support/(Role based portals)

•Technical Integrity

•Information management•Integration•People & process

•Technical Integrity•Maintenance strategyand programs (CBM/RBI)•Inspection static & structures•Condition Monitoring of rotating equipment Inspection static & structures•Decision support

g g q p•Diagnostics / Remote Center/ decision support•Maintenance Strategy Review (RAM / RCM)•Sensors / Wireless / Installation


Capabilities of the alliance - CBM process

■ 6. Recommendation decision:Events are registered and managed in accordance with a predefined process and6. Recommendation accordance with a predefined process and a work order notification issued

■ 5. Condition development analysis:Probability for a failure or breakdown and

6. Recommendation decision

5 Analysis of condition development ycriticality is evaluated and an event issued

■ 4. Technical condition management:Technical condition indicators (TCIs) are used for monitoring of the condition of

5. Analysis of condition development

4. Technical condition management

used for monitoring of the condition of equipment across facilities

■ 3. Condition monitoring and inspection: The equipment is monitored and inspected

3. Condition monitoring and inspection

2 Maintenance monitoring & inspection q p pin accordance with strategy and plan

■ 2. Maintenance, monitoring and inspection planning: After selection of methods for monitoring of

2. Maintenance, monitoring & inspection planning

1. Maintenance strategy development After selection of methods for monitoring of the condition of the equipment, plans for on- and offline monitoring and inspection of the equipment are developed

Line list no. TAG-no.


■ 1. Maintenance strategy development: RCM and RBI methods are used for development of maintenance strategies

What is needed to realise the benefits ofWhat is needed to realise the benefits of Condition Based Maintenance?

(and what the Alliance bring to the table)

SKILLS, EXPERIENCE & SOLUTIONS,

Skills within the allianceSkills within the alliance

Multi Discipline skills

Maintenance engineering and management

Strategy development Maintenance and inspectionStrategy development, Maintenance and inspection Programme developmentCriticality assessment, RAM, FMECA, RCM/ RBI RCAPopulate CMMS

Rotating and mechanical Commissioning of new plant, FAT, Troubleshooting, RCACBM Baseline surveys, Knowledge of a wide range Of CBM systems and tehniques.

Static and structuralInspection management:Inspection management:Identify inspection strategy by means of RBIFull range of NDE/NDT inspection methods of valves, piping, vessels and structures


Multi Discipline skills

Information Systems

CMMS structuring and population for new installations IT systemsCMMS structuring and population for new installations, IT systemsand infrastructure architects, Information Management specialists.Data and information security specialists, Asset lifecycle information,Development of web based reporting systems and development andDevelopment of web based reporting systems and development andsupport of various Condition Monitoring software based on clients’ needs.

Organisational Change

Disciplinescompanies

Strategy and change management consultantsVendors

IO IO

Strategy and change management consultantsDevelop and implement changes to work processes and people behaviour.


ExperienceExperience

Experience with Condition, Performance and Health monitoring tools and techniques

■ The Alliance has substantial experience within condition surveillance of all types of mechanical and static equipment. Our area of competence covers the entire spectrum of data prosessing and analsyingspectrum of data prosessing and analsying.

■ The Alliance has worked on highly sophisticated models for decision support for CM and CBM.

Input Data aquisition Helth assessment Prognostics Diagnostics Presentation

● Event early warning, Residual Lifetime algorithms, 4D visualization

■ Joint R&D initiatives:■ Joint R&D initiatives: ● The Statoil TAIL IO R&D project. ● Involvement in NTNU/SINTEF/IFE IO Centre research programme


Experience – examples of tools/techniques

Within maintenance management ■ Maintenance Strategy Review development and planninggy p p g■ Risk and Reliability Analysis (RBI Analysis, FMECA, RCM/SRCM,

RAM)C i i li■ Criticality assessment

■ Quality assurance and HSE inspections

Within CBM systems and Services (Rotating Equipment)■ Vibration analysis, RCA, Bearing analysis, ultrasonic monitoring■ Thermography, performance monitoring, Flow measurment■ Specialist services


Experience – examples of tools/techniques

Within CBM Systems and Services (Static Equipment)■ All common NDT in-service inspection methods ■ Advanced NDT Technologies: e.g. Eddy currant, Phased array, etc.■ Non Intrusive Inspection of Pressure Vessels and Tanks

St t l I ti M t P■ Structural Inspection Management ProgrammeAnalysis Tools

Bently Nevada System 1 ADRE Datamanager 2000■ Bently Nevada System 1, ADRE, Datamanager 2000■ Prüftechnik Omnitrend, SKF @ptitude Monitoring Suite■ Olympus TomoView Eclips ESBeamTool■ Olympus TomoView, Eclips ESBeamTool ■ AkerSolutions Scale Mapping Thermoghraphic Analysis Tool


Experience – with relevant Information Systems

CMMS■ A large consulting practice working with implementing and supporting

information systems associated with Asset Management All 3 allianceinformation systems associated with Asset Management. All 3 alliance partners have used and are currently users of a number of Computerized Maintenance Management Systems.

Business Intelligence – Data warehouse – Role based Portals■ The Alliance has the necessary toolkits (software and databases) and

skills to provide the right information to the right people/systems at the s s o p o de e g o a o o e g peop e/sys e s a eright time.

Integration plant - enterprise■ IBM's Integrated Information Framework (IIF) integrates real-time

information across multiple source systems. ■ IIF is a key component to enable the overall asset view, to combine■ IIF is a key component to enable the overall asset view, to combine

Condition Indicators at several levels, and a foundation for new applications and analyses.


Experience – with specialised Information Systems

■ Coabis is Aker Solutions’ software product for corrosion management, inspection management and comprehensive integrity management http://www coabis com/management.http://www.coabis.com/

■ Pyramid is the Aker Solutions FMECA, RCM and RBI software tool. Developed over the last six years to assist engineers build optimal maintenance programmes for the Oil & Gas industryprogrammes for the Oil & Gas industry.

■ Delmia 4D simulation and planning software (Dassault Systéme).■ Documented Solutions Program. DSP allows the client to document savings by

the CBM program■ The Aker Solutions owned First Interactive engineering development software:

● Xfactor drilling visualisation.


Track recordCompany Client Project Year Comment

The Alliance StatoilHydro TAIL IO R&D project 2006-2009 Develop leading edge technology within Integrated Operations

The Alliance Aker Drilling CBM Study 2008 CBM implementation

Aker Solutions/ IBM ConocoPhillips Greater Ekofisk area development (GEAD)

2008 - FEED study, including integrated operations (IO) development

SKF Norge BP Ula Valhall Tambour 1993 Present CBM ContractSKF Norge BP Ula, Valhall, Tambour 1993 - Present CBM Contract

SKF Norge Exxon Mobil North Se Production (NSP) 1999 - Present Cross border CBM Contract

SKF Norge Conoco Phillips Tor, 2\4X,J,K,H 1997 - Present Provide systems, Trouble shootingg

Aker Solutions StatoilHydro Tampen V&M 1996 - MMO Frame agreement

Aker Solutions StatoilHydroShell, BPExxonMobile

Various 1998- Condition Monitoring of Static Equipment using Advanced NDT T h l iTechnologies

Aker Solutions BP BPN Maintenance Strategy 2000 - 2001 Overall Maintenance Strategy development

Aker Solutions ConocoPhillipsStatoilHydro

Eldfisk redevelopment studySnorre A Life time extention

2006-2009 Lifetime extension –Technical conditionStatoilHydro Snorre A Life time extention Technical condition and maint. strategy

IBM Major footprint in global oil & gas industry,

Maximo 200x - General

IBM Major footprint in the Oil SAP implementations 199x- General


& Gas industry

Solution ExampleSolution Example

Role based web portal for maintenance operations

Typical Desktop

Tag List

Data from Intergraph, SAP,

Document Listg p , ,

Inspection

Maintenance history (SAP, STAR, Maximo

etc)

Condition Indicators

WI SystemCondition Indicators SKF, AkerSolutions


,

Condition Monitoring and Technical Condition Indicators


Condition Monitoring and Technical Condition Indicators


Technical condition of static equipment


Example of degradation profileExample of degradation profile

Technical condition of rotating equipment■ SKF @ptitude Monitoring Suite software

provides users with trending, detailed analysis and reporting and enables plant-analysis, and reporting and enables plantwide sharing of information

© 2008 Aker Solutions part of AkerSlide 29 © 2008 Aker Solutions

CBM – Key Performance Indicator’s (KPI’s)

■ Top level:● One Plant Overview indicator

■ Overview - function:● HSE: Accidents / hours without / RUH● Production: According to plan / production loss● Production: According to plan / production loss● Plant Maintenance: Condition / Regularity /

Shutdown / AvailabilityS b P d ti / W ll● Subsea: Production / Well

● Transport: Pipes status

■ System: Technical condition indicators■ System: Technical condition indicators● Indicator per system

■ Equipment:q p● Indicator per equipment/equipment group


CBM solutionarchitecture

CBM portalVisualization of status & trends

Event, task & role management6

CM rotating i t

XML

Technical condition indicators (TCI)

CM electrical i

CM static i&

54

nter

pris

e

ps equipment

OPC/WSWS OPC/WS

Integration BusReference Semantic Model

Integrated information f k ( )

equipment equipment

3 & E

cess

ste

p

mai

n

Bildet kan ikke v ises. Datamaskinen har kanskje ikke nok minne til å åpne bildet, eller bildet kan være skadet. Start datamaskinen på nytt, og åpne deretter filen på nytt. Hvis rød x fortsatt v ises, må du kanskje slette bildet og deretter sette det inn på nytt.

OPC

framework (IIF)

Bildet kan ikke v ises. Datamaskinen har kanskje ikke nok minne til å åpne bildet, eller bildet kan være skadet. Start datamaskinen på nytt, og åpne deretter filen på nytt. Hvis rød x fortsatt v ises, må du kanskje slette bildet og deretter sette det inn på nytt.Bildet kan ikke v ises. Datamaskinen har kanskje ikke nok minne til å åpne bildet, eller bildet kan være skadet. Start datamaskinen på nytt, og åpne deretter filen på nytt. Hvis rød x fortsatt v ises, må du kanskje slette bildet og deretter sette det inn på nytt.

Intra installation CB

M p

roc

Dom

DCS

integration Historian

Rotating equipment

i

Electrical equipment

i

Static equipment

i

3

stal

latio

n

C

Compressors, turbines, pumps, …

Instruments, switchgears, switchboards,

drives, …

‐Pipes, tanks, separators, structure, …

‐

Installation 1 Installation 2 Installation 3 …

‐

services services services

Ins


Installation 1 Installation 2 Installation 3 …

An integrated view on production and maintenance

O ti C t

MaintenanceEngineering

Operation Centre

Risk Management

Enterprise Asset Management

Maintenance Strategy

Production Management

Production Strategy

Engineering tools

applications

Event and Incident Management

Maintenance Management

Reference Semantic Model

Real time Integrated Information Framework

Optimized Production

Surveillance and Monitoring

Optimized Maintenance

S h d lProduction

Rotating Equipment

Monitoring Schedule

PRODUCTIONMANIFOLD

3RD STGSEPARATOR

2ND STGSEPARATOR

1ST STGSEPARATOR

TEST

CHOKEVALVE

CRUDEHEATER

TO 1ST STG.SEPARATOR

TO 2ND STGSEPARATOR

PV

PV

PVPRODUCTIONMANIFOLD

3RD STGSEPARATOR

2ND STGSEPARATOR

1ST STGSEPARATOR

TEST

CHOKEVALVE

CRUDEHEATER


TO 2ND STGSEPARATOR

PVPV

PV

PVPV

Data Base

Compressors Pumps Turbines

Static Equipment

Valves Pipes Vessels Electrical

TO 2ND STGSEPARATOR

HYDROCYCLONESTEST SEPARATOR

LV

TO LP FLARE

TESTSEPARATOR A/B

LV

LV

UPGRADE HYDROCYCLONES1ST STG SEPARATORS

HYDROCYCLONES2ND STG SEPARATOR

CRUDECOOLER

CRUDE TRANSFERPUMPS

LV

CRUDE METERINGPACKAGE

OIL TO DSL II

OIL TO DSL I

PRODUCEDWATER PUMP


20H0101INLET HEATER

20H0102INLET HEATER

TESTMANIFOLD

FROM NF E

FROM NF D

CHOKEVALVES

PROD. WATERFLASH TANK

PV

PV

PRODUCED WATEROVER BOARD

PROD.WATERREJECT PUMP

PROD. WATERREJECT TANK

TO LP FLARE

PRODUCED WATERRE-INJECTION

(PWRI)

TO 2ND STGSEPARATOR

OILSKIMMING

FLARE TIP

LV

FROM A TYPICALTLP WELL

CLOSED DRAINPUMP

FROM HAZ. OPEN DRAIN (PUMP)

FROM NON HAZ. OPEN DRAIN (CENTRIFUGE)

FROM HP FLARE KNOCK-OUT DRUMS

PV

MINIFLOW

EPCON CFUPILOT PLANT

50 M PIPELINEEXTENSION

FRAMOMIXER UNIT

New Water Cleaning Plant in M31W

EPCON Compact Flotation Units

Export OilSpec: WiO < 0,5%

Produced Water to seaSpec: OiW < 40 ppmFrom 2006: OiW < 30 ppm

(TO 1ST STG. SEPARATORProduced Water Outlet

or Closed Drain)


REJECT (Water, Oil and Gas)

PWRI-PUMPS

LV

LV

LV

LV

LP Flare KO Drum

Closed Drain

Due to Epcon CFU’s use of flotation gas, Heidrun’s gas regeneration

capacity has to be increased as well.

TO 2ND STGSEPARATOR

HYDROCYCLONESTEST SEPARATOR

LV

TO LP FLARE

TESTSEPARATOR A/B

LV

LV

UPGRADE HYDROCYCLONES1ST STG SEPARATORS

HYDROCYCLONES2ND STG SEPARATOR

CRUDECOOLER

CRUDE TRANSFERPUMPS

LVLV

CRUDE METERINGPACKAGE

OIL TO DSL II

OIL TO DSL I

PRODUCEDWATER PUMP


20H0101INLET HEATER

20H0102INLET HEATER

TESTMANIFOLD

FROM NF E

FROM NF D

CHOKEVALVES

PROD. WATERFLASH TANK

PVPV

PVPV

PRODUCED WATEROVER BOARD

PROD.WATERREJECT PUMP

PROD. WATERREJECT TANK

TO LP FLARE

PRODUCED WATERRE-INJECTION

(PWRI)

TO 2ND STGSEPARATOR

OILSKIMMING

FLARE TIP

LVLV

FROM A TYPICALTLP WELL

CLOSED DRAINPUMP

FROM HAZ. OPEN DRAIN (PUMP)

FROM NON HAZ. OPEN DRAIN (CENTRIFUGE)

FROM HP FLARE KNOCK-OUT DRUMS

PVPV

MINIFLOW

EPCON CFUPILOT PLANT


FRAMOMIXER UNIT

New Water Cleaning Plant in M31W

EPCON Compact Flotation Units

Export OilSpec: WiO < 0,5%

Produced Water to seaSpec: OiW < 40 ppmFrom 2006: OiW < 30 ppm

(TO 1ST STG. SEPARATORProduced Water Outlet

or Closed Drain)


REJECT (Water, Oil and Gas)

PWRI-PUMPS

LV

LV

LV

LV

LP Flare KO Drum

Closed Drain

Due to Epcon CFU’s use of flotation gas, Heidrun’s gas regeneration

capacity has to be increased as well.

Production plant


Support structureSupport structure

Support organisation and structure

■ A tailored support organisation may be put up according to the clients needs and requirements. We have the capability to build a complete support group with the following properties:complete support group with the following properties:● Single point of contact.● Support organized under ITIL (industry best practise) work

processes withp ocesses■ 1st line Service Desk■ 2nd line Problem solving■ 3rd line Vendor Supportpp

● 24*7 Availability● Integrated at Clients office and/or own support centres● Support centres will staffed with maintenance specialists,● Support centres will staffed with maintenance specialists,

engineers etc. all according to your needs. ■ For systems which we do not have necessary skill level now, we will

do training and/or other measures to meet the required service leveldo training and/or other measures to meet the required service level. ■ Through this support centre we will also be able to offer training to

Client personnel and contractors


How to get started?How to get started?

Proof of conceptProof of concept

CBM Pilot

■ Scope:● One group of critical equipment - i.e. Water Injection Pumps

■ Definitions:● Performance and technical indicators aligned with the Maintenance philosophy/strategy

■ Time Period:● Start pilot – be ready to production start● Start pilot be ready to production start.

■ Access to source data:● We need access to data sources; DCS Historian, CMMS, CM, Technical Doc., Instrument

Index

f■ Pilot infrastructure● Run pilot in IBM Stavanger CoE, access data through SOIL or internet

■ Deliverables:● Portal for presentation of the Use Cases available on Internet or Soil● Integration of data sources (available on SOIL/Internet)● Calculation and aggregation and condition indicators and measurements


Conceptual sketch

Presentation layer:Presentation layer:■Portal with information levels; Field, Platform, System and Equipment

Business Logic layer:Business Logic layer:f f f■Processing of information before

presentationi.e. calculation of performance indicators an dtechnical indicators, aggregation, analysis, predictions, trending,

Presentation Layer

Business Logic Layer

Statoil Global Support CentersStatoil Global Support Centers

y p g

Integration Layer: Integration Layer: ■Capture data from all systemsIntegration Layer

Business Logic Layer

RT measurements, Alarms/EventsWork Orders, Drawings, Data Sheets

DCS CM(SKF)

CMMSCM Techn.Info


Portal Information Levels

Field units/installationsField units/installationsTrafic light indication of the aggregated Technical Condition

f Sf SPlatform SystemsPlatform SystemsTrafic light indication on each System’s Technical Condition

EquipmentEquipmentEquipmentEquipmentDetail illustration of equipment with real time measusrements and indicators

Instrument Instrument All meassurements and calculated condition indicaters for specific instrument


Example Use Case 1 – Field View

Alfa FieldAlfa Field Beta FieldBeta Field


Example Use Case 2 – System View

Information Information provided:provided:pp• Inspection history and

planned • Maintenance history• Active Work Orders• Drawings; ISO, P&ID• Criticality analysis

RBI l i• RBI analysis


Example Use Case 3 – Equipment view

Information provided:Information provided:■Inspection history and planned ■Maintenance history■Active Work Orders■Drawings; ISO, P&ID■RT Measurements; Speed, amp, press, temp, flow■Bearing parts number D t il f th h l■Details for the pump-wheel

■Product Data Sheet - KW etc.■Degradation and failure history■Criticality analysis■Criticality analysis■RBI analysis


Example Use Case 4 - Collaboration

Functionality:Functionality:■Share work panelsO h Off h

Statoil Global Support CentersStatoil Global Support Centers

Onshore – Offshore■Link to Vendor and upload of info – RT access

MaintenanceMaintenanceplanning staffplanning staffWork ordersWork orders

(WO)(WO)

OffshoreOffshoremaintenance crewmaintenance crew

■Task follow-up● Assign, status,

deadline, history

NotificationNotificationFacilityFacility•• Integration ofIntegration of

■Notification creation

BaroniaBaronia

•• Integration of Integration of information sourcesinformation sources

Online & offline Online & offline

Onshore CM centreOnshore CM centre•• Monitoring & analysis of Monitoring & analysis of

conditioncondition•• Management of eventsManagement of events

measurementsmeasurements


A partnership to solve an industry challenge


Documents

Condition Based MaintenanceCondition Based Maintenancekonferanse.maintech.no/fileshare/filarkivroot/Konferanse/2010... · Condition Based MaintenanceCondition Based Maintenance