Post on 13-Mar-2018
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
© 2008 Aker Solutions part of AkerSlide 3
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?
© 2008 Aker Solutions part of AkerSlide 5
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)
Equipment monitoring systemsFa
cilit
yplanning to take both steps simultaneouslyo To standardize and scale its CM
processes and solutions Step 1Step 1
Control system(DCS)
Equipment monitoring systemsFa
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
© 2008 Aker Solutions part of AkerSlide 6
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%
© 2008 Aker Solutions part of AkerSlide 7
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
© 2008 Aker Solutions part of AkerSlide 8
The AllianceThe Alliance
A partnership to solve an industry challenge
© 2008 Aker Solutions part of AkerSlide 10
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
© 2008 Aker Solutions part of AkerSlide 11
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.
© 2008 Aker Solutions part of AkerSlide 12
■ 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
© 2008 Aker Solutions part of AkerSlide 15
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.
© 2008 Aker Solutions part of AkerSlide 16
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
© 2008 Aker Solutions part of AkerSlide 18
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
© 2008 Aker Solutions part of AkerSlide 19
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
© 2008 Aker Solutions part of AkerSlide 20
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.
© 2008 Aker Solutions part of AkerSlide 21
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.
© 2008 Aker Solutions part of AkerSlide 22
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
© 2008 Aker Solutions part of AkerSlide 23
& 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
© 2008 Aker Solutions part of AkerSlide 25
,
Condition Monitoring and Technical Condition Indicators
© 2008 Aker Solutions part of AkerSlide 26
Condition Monitoring and Technical Condition Indicators
© 2008 Aker Solutions part of AkerSlide 27
Technical condition of static equipment
© 2008 Aker Solutions part of AkerSlide 28
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
© 2008 Aker Solutions part of AkerSlide 30
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
© 2008 Aker Solutions part of AkerSlide 31
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 1ST STG.SEPARATOR
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
TO 1ST STG.SEPARATOR
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)
50 M PIPELINEEXTENSION
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
TO 1ST STG.SEPARATOR
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
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)
50 M PIPELINEEXTENSION
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
© 2008 Aker Solutions part of AkerSlide 32
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
© 2008 Aker Solutions part of AkerSlide 34
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
© 2008 Aker Solutions part of AkerSlide 36
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
© 2008 Aker Solutions part of AkerSlide 37
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
© 2008 Aker Solutions part of AkerSlide 38
Example Use Case 1 – Field View
Alfa FieldAlfa Field Beta FieldBeta Field
© 2008 Aker Solutions part of AkerSlide 39
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
© 2008 Aker Solutions part of AkerSlide 40
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
© 2008 Aker Solutions part of AkerSlide 41
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
© 2008 Aker Solutions part of AkerSlide 42
A partnership to solve an industry challenge
© 2008 Aker Solutions part of AkerSlide 43