ABB Asset Management System - Ifea … · ABB Asset Management System ... ABB and 3rd party PLC &...
Transcript of ABB Asset Management System - Ifea … · ABB Asset Management System ... ABB and 3rd party PLC &...
© ABB GroupSeptember 21, 2012 | Slide 1
Tor Ole Bang-Steinsvik, Integrated Operations
ABB Asset Management SystemEICT Equipment Condition MonitoringPerformance Monitoring
© ABB Group September 21, 2012 | Slide 2
72+ M.Eng and 8 Ph.Dwithin:
Process Automation Eng.Computer ScienceMechanical Eng.Electrical Eng.Chemical Eng.Petroleum Eng.Geology
ABB Integrated Operations
© ABB GroupSeptember 21, 2012 | Slide 3
Asset Management - Why?Top Level System
Overall ViewCustomized GUI on enterprise level – MS Sharepoint
Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance Monitoring
Today’s topics
© ABB GroupSeptember 21, 2012 | Slide 4
ElCT system - FPSO
Base System servers Panel 800 System Workplaces
Extended Operator Workplaces
AC 800MHigh IntegrityController
ABB and 3rd partyPLC & DCS
Fire & GasAlam units
Shut-down
WirelessHART
S900 I/O
S800 I/O
WirelessHARTGateway
LV Switchgear
Variable Speed Drive
MotorController
AC 800MController
Protection &Control IED
Plant Network,ERP, CMMS…
System Networks
Field Networks
SubstationAutomation
ProcessElectrification
ProcessInstrumentation Safety PLC & DCS
IEC
618
50
PR
OFI
BU
S /
PR
OFI
NE
T
MO
DB
US
Mod
uleb
us
System integration
The Challenge – Reduce Operational Expenditures
Distribution1 Safety equipment 11,7 %2 Electric power distribution 11,3 %3 Instrumentation 10,6 %4 Piping specialities 8,7 %5 Lifting 8,1 %6 Pressure vessels and storage tanks 5,7 %7 Piping, pipeline, risers and umbilical 5,0 %8 AC, equipment for refrigeration 5,0 %9 Turbines 4,4 %10 Manually operated valves 4,2 %11 Pumps 3,8 %12 Power generation/transformation 3,8 %13 Communication equipment 3,1 %14 Other 3,1 %15 Safety relief valves 3,0 %16 Combustion engines 2,6 %17 Actuator operated valves 0,9 %18 Not relevant 5,2 %
100,0 %
Maintenance cost distribution for 10 north-sea fields: 40% EIT
Operational expenditures at the Norwegian shelf, according to DNV studies
© ABB GroupSeptember 21, 2012 | Slide 7© ABB Group September 21, 2012 | Slide 7
Condition MonitoringPhilosophies
Reactive Maintenance -”Fix when error occurs”
Costly with regards toProcess downtimeConsequential lossesOvertime costsSpare part storage
Preventive Maintenance -”According to plan”
ProsAvoids break down
Increased equipment lifetime
ConsUnnessary maintenance can occure
Risk of introducing faults
Predictive Maintenance -”According to actual need”See next slide
© ABB GroupSeptember 21, 2012 | Slide 8© ABB Group September 21, 2012 | Slide 8
Predictive Maintenance”According to actual need”
30-40% more cost efficient than reactive maintenance (*)8-12% more cost efficient than preventive maintenance (*)Increased lifetimeLess need for storageSafer (HSE)
Online condition monitoring makes it possible to predict condition - based on long time logging and deeper analysis
* Source: US Department of Energy (http://www1.eere.energy.gov/femp/program/om_predictive.html)
© ABB GroupSeptember 21, 2012 | Slide 9
Conditon Monitoring System
Note:Time Synchronization
View
Signals
OPC/Modbus/etc.
DCS
(Electrical) (Vibration) (Process)
Portal
(Performance Monitoring)
© ABB GroupSeptember 21, 2012 | Slide 10
Today’s topics
Asset Management - Why?Top Level System
Overall ViewCustomized GUI on enterprise level – MS Sharepoint
Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance MonitoringReferences
© ABB GroupSeptember 21, 2012 | Slide 11
Solution Hierarchy and Decision LoopsLe
vels
0-2
Leve
ls 3
-4
Local MMI
MaintenanceWorkplace
ProcessInsightPerformance
Monitoring
ERP/EAM
SpecialisedDashboards
SystemViewer
Technology Exams
© ABB GroupSeptember 21, 2012 | Slide 12
• Fast Raw Data Storage
Alarm & Events
Aggregates
Other RDBMS Data
800xA Historian
OPC
.NET/WSODBC
800xA History Database
Report Engine
800xAFirewall Firewall
800xAFirewall
Excel Access
DC
Calculation Engine
DC DC
“Advanced Reports”
Graphics & Trends
Alarms Analysis
$PIMS
ECS
cpmPlusEnterprise Connectivity
Business Systems
ECS PlugIn
cpmPlus Data Collectorpure TCP/IP based!auto-reconnect!’buffered send’ !Supports 800xA Log
Configuration Aspects
© ABB GroupSeptember 21, 2012 | Slide 13
ABB Industrial IT Platform
Top Level System Architecture
Asset Optimizer Maintenance Workplace
800xA History
Process Historian + Model and information (ECS)
Data Warehouse
MS Sharepoint
MS BI Reporting Services
ABB IO Web Applications /
Web Parts
3rd party Web Applications /
Web Parts
Plant Network
Technical Networks
PerformanceOptimization
Userconfigurable
Web GUI
OPC DA/HDAWeb Services
BAPIWeb Services
ISA-95ISO 15926
Asset Management /
Expert Applications
Data Collector in SAS
© ABB GroupSeptember 21, 2012 | Slide 14
MS Sharepoint – Compressor Drive Monitor example
© ABB GroupSeptember 21, 2012 | Slide 15
Today’s topics
Asset Management - Why?Top Level System
Overall ViewCustomized GUI on enterprise level – MS Sharepoint
Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance Monitoring
© ABB GroupSeptember 21, 2012 | Slide 16
ABB Industrial IT Platform
Top Level System Architecture
Asset Optimizer Maintenance Workplace
800xA History
Process Historian + Model and information (ECS)
Data Warehouse
MS Sharepoint
MS BI Reporting Services
ABB IO Web Applications /
Web Parts
3rd party Web Applications /
Web Parts
Plant Network
Technical Networks
PerformanceOptimization
Userconfigurable
Web GUI
OPC DA/HDAWeb Services
BAPIWeb Services
ISA-95ISO 15926
Asset Management /
Expert Applications
Data Collector inSAS
© ABB GroupSeptember 21, 2012 | Slide 17
Continuous Monitoring of all sub-systems in one workplaceAlarm including cause and suggested actionFacilitates drill-down to detailed diagnostic functionsSurveillance and Statistics for maintenance planning
Platform for collaboration between user groups, engineering disciplines and locations
Monitoring
Reporting
Analyzing
Decision
ActionSubmit
Maintenance Workplace
Notify
© ABB GroupSeptember 21, 2012 | Slide 18
Maintenance WorkplaceCommon Maintenance view for all Assets
Asset Monitors identify severity of asset performance degradation
© ABB GroupSeptember 21, 2012 | Slide 19
What is an Asset Monitor?
Asset specific function block that verifies asset related input dataaccording implemented maintenance and diagnostic rulesUse real-time production and control dataKeep “score” for the asset performanceCorrelation of data in asset contextProvide visibility to “big picture”Transmit the information to those able to act
Other personnelOther systems
Asset MonitorProduction Personnel Data
Automation System Data
MES/ERP Data
SCE DataReal-time Asset Information
© ABB GroupSeptember 21, 2012 | Slide 20
Maintenance System Topology
Maintenance Workplace2nd. and 3rd.
Line users
© ABB GroupSeptember 21, 2012 | Slide 21
Today’s topics
Asset Management - Why?Top Level System
Overall ViewCustomized GUI on enterprise level – MS Sharepoint
Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance Monitoring
© ABB GroupSeptember 21, 2012 | Slide 22
Electrical system CM
Drive Monitor
Medium Voltage SWG Monitor
Transformer Monitor
HV SWG Monitor
Low Voltage ACB and MCC
Monitor
Sea cable Monitor
Online Vibration Monitor
Wireless Vibration Monitor
© ABB GroupSeptember 21, 2012 | Slide 23
HV/MV Switchgear Monitor – Relion Protection Relays
Trip coil
Contact wear
Energizing circuit
Breaker travel time
Breaker inactive time
Spring charging time
Transient disturbance recorder
© ABB GroupSeptember 21, 2012 | Slide 24
HV/MV Switchgear Monitor – Relion Protection Relays
Electro Condition Monitoring – IEC61850
© ABB GroupSeptember 21, 2012 | Slide 25
Sensycal Temperature Monitoring – MV SWG
Contactless IR temperaturemonitoring of contact points and conductor rails on MV-level
Reporting to MaintenanceWorkplace by Asset Monitor
© ABB GroupSeptember 21, 2012 | Slide 26
LV Circuit Breaker Monitor
Local bus unit
Trip coil
Contacts
CB statuscontacts
Temperaturesensor
EP010
Trip unit,electronic
Currentsensors
© ABB GroupSeptember 21, 2012 | Slide 27
LV Motor Control Centre Monitor - MNS iS
© ABB GroupSeptember 21, 2012 | Slide 28
MNS iS
© ABB GroupSeptember 21, 2012 | Slide 29
DriveMonitorTM
DriveMonitorTM diagnostic system:Early detection of potential failureAlerts including possible cause and recommendations for corrective actions through Maintenance WorkplaceRemote access allows support from external expertPredefined diagnostic logging functions, processing and reportingMonitoring of drive’s performance, and, if required, other shaft line components (main circuit breaker, transformer, motor)
© ABB GroupSeptember 21, 2012 | Slide 30
DriveMonitorTM
© ABB GroupSeptember 21, 2012 | Slide 31
TEC – Transformer Monitor
The TEC (Transformer Electronic Control) is a diagnostic system which provides:Statements about the operating condition and load ability predictionDiagnoses and recommendations for corrective actions if problems with the transformer should occur (oil/winding temperature, tap-changer wear, moisture and hydrogen content in oil)Prediction of the consumed lifetime based on overload forecasting and winding hot-spot calculationsOptimum cooling performance according to load and controlled wear on cooling pumps and fans
© ABB GroupSeptember 21, 2012 | Slide 32
MV/LV Dry Transformer Monitoring
Monitoring of windingtemperaturesReporting to MaintenanceWorkplace by Asset MonitorWeb-MMI accessiblethrough MaintenenanceWorkplce
© ABB GroupSeptember 21, 2012 | Slide 33
Sea cable monitoring
.
Based on fiber optic distributed temperature sensing (DTS)
Provides continuous and repeatable measurements, in real-time, of the location and the temperature of many thousands of points along the optical fiber sensor.
The environment of a submarine cable, particularly at the ends, can change. Monitoring the temperature will alert the maintenance system should the cable, for example, be stretched or bent, since the stress on the cable will change.
Individual sections of the cable can be identified as different zones (i.e around a buoy) that can be independently programmed to generate an alarm via the maintenance system when the temperature in any zones reaches a pre-set limit, thus helping to both protect the cable and prevent outages.
Graphical user interfaces, temperature profiles and data are integrated into Asset Optimizer.
© ABB GroupSeptember 21, 2012 | Slide 34
Today’s topics
Asset Management - Why?Top Level System
Overall ViewCustomized GUI on enterprise level – MS Sharepoint
Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance Monitoring
© ABB GroupSeptember 21, 2012 | Slide 35
Vibration Monitoring- the objective
Proven technology for predictive maintenance of rotating equipment
Detect incipient failure
planand
prepare Shutdown and
repair
Cost effective means of avoiding production loss and minimising
maintenance costManual data gathering today - Ideal opportunity for wireless technology
Protection system- to prevent catastrophic failure
Primary safety system with safety critical performance standards
Shut machine
down within msec
Wired systems are preferable (for now)
© ABB GroupSeptember 21, 2012 | Slide 36
© ABB Group September 21, 2012 | Slide 36
Wireless Vibration System – WiMon100
© ABB GroupSeptember 21, 2012 | Slide 37
Condition Monitoring of rotating equipment
(OPC)Asset Monitor Integration / OPC
Vibration serverABB Analyst frequency analysis 800xA Asset Optimizer
Maintenance Workplace
© ABB GroupSeptember 21, 2012 | Slide 38
Today’s topics
Asset Management - Why?Top Level System
Overall ViewCustomized GUI on enterprise level – MS Sharepoint
Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitioringPC, Network and Software MonitoringPerformance Monitoring
© ABB GroupSeptember 21, 2012 | Slide 39
Field Device Monitor
HART based instruments and field devices monitored via the Maintenance Workplace
Transmitters
Gas detectors
Valve positioners
Maintenance Workplace provides easy access to the instrument vendors device specific MMI’s (e.g. HART DTM’s)
Root-cause fault finding
Performance optimization
Co-operation with Solberg Andersen on Valve Monitoring
PST by Metso Positioners
Valvewatch for selected safetyvalves
FieldKey - WirelessHART Adapter
© ABB GroupSeptember 21, 2012 | Slide 41
Today’s topics
Asset Management - Why?Top Level System
Overall ViewCustomized GUI on enterprise level – MS Sharepoint
Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance Monitoring
© ABB GroupSeptember 21, 2012 | Slide 42
PC, Network and Software Monitor
All IT assets monitored via the Maintenance Workplace
Servers
Switches
Controllers
Maintenance Workplace provides easy access to the device specific MMI’s
Easy fault finding
Performance
© ABB GroupSeptember 21, 2012 | Slide 43
Today’s topics
Asset Management - Why?Top Level System
Overall ViewCustomized GUI on enterprise level – MS Sharepoint
Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance Monitoring
Asset Management – two main work processes
• Examples include:• Mecanical faults with
equipment• Sensor failures• Electrical faults• Detectors
Emergingequipment fault
• Fault detected by monitor
• Alert plant operators ofemerging fault(Alarm/Event)
• Initiate investigation
Alert and investigate • Inspect equipment
• Perform diagnosticsusing available tools
• Consult with Subjectmatter experts
Diagnose
• Generate work orders• Perform maintenance
Decide and implement
• Examples include:• Reduced efficiency of pump
and compressor strings• Fouling in heat exchangers• Reduced separator efficiency• etc
Performancedegradation
• Automatic identification ofdegraded performance
• Assessment of criticalty• Suggested actions• Notification to relevant personell
Identify • Detailed evaluation of rootcause
• Detailed assessment ofcriticality
• Update identificationmodelsand suggestes actions
Diagnose
• Update maintenance plan• Issue work orders
Decide and implement
Field Equipment ManagementMainly targeting maintenance
as part of daily operationShort decision cyclesTightly linked to or integrated in control system
Process Equipment ManagementDiagnostics supporting long-
term maintenance planning and managementLonger decision cyclesLinked to corporate maintenance management systems
Knowledge transfer
© ABB GroupSeptember 21, 2012 | Slide 45
Features:Standard performance tool library (DIN, ASME) Generic models (Pumps, Compressor, Heat
Exchangers, etc.)
Online thermodynamic modelsContinuous comparison between actual and expected plant performance. => Calculates performance deviationsTie-back to Maintenance Workplacefor maintenance planning
Benefits:Reduces fuel costsImproves predictive maintenanceEarly detection of degradationsAccepted calculation norms Typical payback <2 years
ProcessInsight Performance Monitoring
Performance deviations
© ABB GroupSeptember 21, 2012 | Slide 47© ABB Group September 21, 2012 | Slide 47
Shell Ormen LangeOrmen Lange Service EnvironmentTM Agreement
ABB is Single Point of Contact for all Automation System ServiceIndependent of vendorIndependent of the case type (Incident/ Event etc)Change and Configuration ManagementUpdated Site Inventory independent of vendor
ABB perform & assist in System Operations Remote work/collaboration facility at ABB premises
Process Tuning SupportRemote system condition monitoring
Automation System MonitoringTelecom System MonitoringInstrument MonitoringHeat Exchanger Monitoring
ABB responsible for System evolution planning
BP Valhall - Asset Management provided by ABB
Automation / InstrumentationHART Field Device MonitoringTransmitter Discrepancy MonitoringAnalyzer MonitoringSafety/Shutdown systems
Automatic Shutdown ReportValve Verification and Partial Stroke Testing
ICSS and Telecom Monitoring (servers, networks, I/O controllers, software processes)
ElectricalElectrical switchgears, LV and MVPower from shore HVDCLight offshore and onshore moduleTransformersUPS and Bender
ProcessFilters, Hydraulic skid, JTValve
Goliat FPSO - Condition Monitoring System
Asset Management System (AMS)
Condition Monitoring of Rotating Equipment
Turbines Compressors and diesel driven generatorsVibration and Performance Monitoring System
Valve MonitoringSmart Instrument MonitoringCondition Monitoring for Static Equipment Metering System MonitoringElectrical Monitoring
Monitoring of the sea cable UPS MonitoringDry transformersOil Filled TransformersCircuit breaker monitoringHeat TracingLow Voltage Switchboards High Voltage MonitoringVariable Speed Drive Monitoring
HVAC MonitoringFire and Gas Detectors MonitoringSub Sea MonitoringMarine Monitoring
Monitoring of the hull structureOffloading StationAnchor WinchesOffshore Cranes
Analyzers MonitoringTelecommunication Surveillance and Monitoring Systems PC, Network and Software MonitoringPerformance MonitoringRotating equipment performance monitoring Loop Performance Monitoring
© ABB Group September 21, 2012 | Slide 49