Risk Based Maintenance Strategy - Marcogazmarcogaz.org/egatec2011/PS4/PS4E_Koutny_egatec2011.pdf ·...

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Risk Based Maintenance Strategy at NET4GAS Petr Koutný Head Of Asset Operation NET4GAS, s.r.o. Copenhagen Denmark May 13th, 2011

Transcript of Risk Based Maintenance Strategy - Marcogazmarcogaz.org/egatec2011/PS4/PS4E_Koutny_egatec2011.pdf ·...

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Risk Based Maintenance Strategy at NET4GAS

Petr Koutný Head Of Asset Operation NET4GAS, s.r.o.

Copenhagen Denmark

May 13th, 2011

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Content

1. History of Czech gas industry 2. NET4GAS, s.r.o. o Transmition grid o Gas flow o Maintenance in N4G

3. Maintenance Strategy Support o 1st step - Pipelines o 2nd step - RBM/CBM for non-pipeline assets using PIMS

modules o 3rd step - Dynamic Asset Simulation - DAS o Goals

4. Ongoing Projects

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1. History of the Czech Gas Industry

1847 1919

1997 1994

1973

1931 1967

2006

1971

2010

First town gas deliveries from

Prague Gas Works

Foundation of International

Gas Union

Foundation of the Czechoslovak Gas and Water Association

First deliveries of NG through Brotherhood

Pipeline

2002

2011

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2. NET4GAS, s.r.o.

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New address: NET4GAS, s.r.o. Na Hřebenech II 1718/8 CZ 140 21 Praha 4 – Nusle T: +420 220 221 111

• Part of RWE International Group

• Exclusive holder of license for operation of gas transmission system in CZ

• Providing equal access to gas transmission system for all natural gas traders

• Transmits more than 30 BCM of natural gas per year for international customers, 10 BCM for Czech Republic

• Member of Czech Gas Union or European Association of Transmission System Operators (GTE)

• 15 bil CZK investment to the transmission grid till 2020

Key Figures for 2010 M CZK M EUR

EBITDA 8 246 330

Operation result 5 981 239

Profit before taxation 6 204 248

Profit after taxation 5 026 201

Investments 759 30

Number of employees 519

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2. NET4GAS Transmission Grid

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Main activities:

Gas Transport to foreign clients Gas Transport to intrastate customers Maintenance services

Comprises:

Border Delivery Stations 4 BDS In construction 2 Intrastate Delivery Stations 86 Compressor Stations 5 CS Installed Power 297 MW UGS of different operators 9 (with total capacity 3,25 BCM)

Technical Data:

3,640 km of gas line Pressure 4.0 to 8.4 MPa, Diameters up to DN 1400

STORK

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2. NET4GAS Transmission Grid

SAYDA

HORA SV. KATEŘINY

WAIDHAUS

Transmission grid 2011

KOUŘIM

KRALICE N. O.

BŘECLAV HOSTIM VESELÍ N. L. MALEŠOVICE

HOSPOZÍN

Border Delivery Station

Compressor Station

ROZVADOV

Junction Point

LANŽHOT

OLBERNHAU

Avg. Gas consumption of CZECH REPUBLIC

cz

cz

cz

cz

cz

cz

Delivery Station

25 mil.m3/d

35 mil.m3/d

35 mil.m3/d

35 mil.m3/d

70 mil.m3/d

95 mil.m3/d

30 mil.m3/d

70 mil.m3/d

180 mil.m3/d

25 mil.m3/d

45 mil.m3/d

93 mil.m3/d

25 mil.m3/d

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2. NET4GAS Pipelines - Design

Total length 3 640 km Diameters, mostly 20“ - 56“ (DN 500 – DN 1400) MAOP 7.35 MPa, 6.3 MPa, 6.1 MPa, 8.4 MPa ) Material steel (X 52 - X 70) Coating bitumen tape ( in field coating ) factory PE epoxy ( small sections - repairs ) CP (Cathodic protection) all pipelines, permanently, compressor stations without protection NDT testing 100% of welds were tested Ground cover > 0,8 m Safety zone 160 m both sides from pipeline Protected zone 4 m both sides from pipeline

Transit pipelines are 100% piggable and regularly inspected using internal inspection. Intrastate pipelines are mostly piggable as well, condition of unpiggable sections is regularly assessed.

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2. Maintenance costs by Asset type

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Pipeline Transit; 69 %; (2460 km)

Pipeline Domestic; 12 %; (1180 km)

Compressor Stations; 15 %; (5 CS)

Delivery Stations Transit; 3 %; (4 DS)

Delivery Stations Domestic; 1 %; (86 DS)

Value by Asset type

Pipeline Transit; 40 %

Pipeline Domestic; 12 % Compressor Stations; 36 %

Delivery Stations Transit; 7 %

Delivery Stations Domestic; 5 %

Maintenance costs by Asset type

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2. Maintenance by type

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Maintenance after Failure

Regular Maintenance

Casing Repairs 3% Cathodic Protection

6% CS - Other Basic

Maintenance 9%

CS - Maintenance 14%

I & C 5%

Internal Inspection 3%

Other Basic Maintenance 17%

Pipeline Inspection 4%

Pipeline Maintenance

20%

Valve Replacement 19%

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3. Maintenance Strategy Support Asset management in progress

Asset Condition

pipelines PIMS

Asset Strategy

Long-term

Financial plan

Scenarios

OPEX, CAPEX

DAS

Asset Condition

Pipelines Non-pipeline assets Other Assets

PIMS/ RBM/CBM

ILI since 1988 Turbo Sets Diagnostics since 1980

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194 km 10.307 km

1988 2010

Cumulative Inspected length

year

- Safety and reliability of N4G pipelines is based on reinspections - Maximum inspection interval - 8 years (Czech Gas Standard) - Used MFL & TFI methods in combination with mapping unit - More than 2500 defects repaired in 20 years

3. Maintenance Strategy Support

1st step – Pipelines

PIMS - Pipeline Integrity Management System

Main Sources: Internal Inspections GIS Soil type Crossings Cathodic Protection

Functions: Merge and View data from different sources Defect assessment Risk assessment Repairs planning

194 km 10.307 km

1988 2010

Cumulative Inspected length

year

Participiants: Logica ATP Gasunie

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SAP PM

PIMS

3. Maintenance Strategy Support - 1st step

Pipeline Repair Process

Defect assesment, proposed to dig out

Approval of repair

Internal inspection External Inspection

Asset condition data

Infield Defect Assessment and Repair

GIS

Notification

SAP PM order closing

Repair documentation

Plan against

final solution

Protocol saved in DMS

Final Documentation

Link to Protocol

Order

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3. Maintenance Strategy Support

2nd step - RBM/CBM for non-pipeline assets using PIMS modules

Goals: • NET4GAS as a responsible gas transport system operator needs:

• Information on actual status of all assets on transport system regarding their usability for operation (Border and Intrastate Delivery Stations, Turbo sets, Valve Stations, Control Systems, Valves, Other important assets)

• Prediction of life time of individual assets and assessment of their current condition from life cycle point of view (as a basis for decision on maintenance measures and optimization of maintenance plans)

• Reliable information to prove acceptable costs of operation and maintenance for Controlling and Regulatory Objectives

• Assumptions:

• Information shall be provided in functional location hierarchy detail with possibility of aggregation to higher level objects

• Information shall reflect the actual asset status (immediate, long-term) • Information shall be used both for daily operations and maintenance and for

planning of large scale maintenance measures in short, mid and long term horizon

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SAP PM

PIMS / RBM / CBM

SAP BI

DAS

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Notifica-tions

FL - assets

Orders Immediate asset status

Asset condition + proposed maintenance measures

Risk model

Data for assessment

Asset condition

Measures

Plan + costs

FL

Status

Maintenance costs

Condition

Plan + planned costs

Status of open notifications

FL

Operational tool for asset and maintenance

Analytical tool for diagnostics and maintenance

Management tool for operations and maintenance

Asset status

Asset condition + costs

Summary asset information (status, condition, technical + financial data)

Strategic tool of asset management

FL Long-term financial plan OPEX, CAPEX

Other inputs

Long-term financial plan OPEX, CAPEX

Handhelds

FL - assets

GIS

Asset strategy

Long-term financial planning

3. Maintenance Strategy Support 2nd step – PIMS/RBM/CBM for non-pipeline assets Pipeline Integrity Management System / Risk Based Management / Condition Based Management

Architecture of solution

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Risk decomposition Risk groups Risk factors

Constant properties 35%

Technical condition 65%

Significance 100%

Probability of failure 70%

Consequences of failure 30%

Total risk Age 70%

Risk of technology 30%

Mechanical condition 20%

Internal leak 40%

External leak 40%

Significance for transport 50%

Extra costs of failure 50%

Assessment scheme example

etc.

etc. etc.

etc. etc.

Categories 0 to 10 0

11 to 25 3

over 25 10

V0 leak 0

V1 leak 3

V2 leak 7

V3 leak 10

etc.

etc.

C

weight

score

direct assignment to specific risk segment

3. Maintenance Strategy Support

2nd step - Principles of RBM/CBM method

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3. Maintenance Strategy Support

2nd step - Asset ranking using risk matrix RBM/CBM

Risk matrix shows distribution of risk related to specific class of assets within the company

Risk is presented as relation of:

– probability of failure – and consequences of failure

100

90

1 1

80

70

1

60

1 3 3 2 1

50

1 1 2 1 1 21 2

40

22 5 1 1 1 1

30

59 52 1 1

20

2

10

0 10 20 30 40 50 60 70 80 90 100

Probability of failure

Con

sequ

ence

s of

failu

re

Risk Matrix 2010 Example: Control systems

Probability of failure [%]

Cons

eque

nces

of f

ailu

re [%

]

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Gesamtkosten

0

2

4

6

8

10

12

14

16

18

20

0 10 20 30 40

Mil

lio

nen

Simulationszeit (a)

Aktuelle StrategieAlternative Strategie

Gesamtkosten

0

2

4

6

8

10

12

14

16

18

20

0 10 20 30 40

Mil

lio

nen

Simulationszeit (a)

Aktuelle StrategieAlternative Strategie

Dynamic Asset Simulation

2010: Lifecycle only partly shown View of the complete lifecycle

Strategy 1

Strategy 2

Strategy 1

Strategy 2

Total expenses Total expenses

2080 2010 2080 2010

Lifecycle Lifecycle

Dynamic Asset Simulation in NET4GAS: - supports to identify sustainable/long-term asset strategies - simulate the mid-term and long-term effects of business decisions - identify the sensitivity of different measures, especially OPEX and CAPEX - quantify qualitative effects and interactions regarding different competitive objectives

3. Maintenance Strategy Support

3rd step - Dynamic Asset Simulation - DAS

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3. Maintenance Strategy Support

3rd step - Dynamic Asset Simulation - DAS Simulation of OPEX and CAPEX trend

Asset Tree

Asset Distribution according to age and technical status

85 % Good

10 % Middle

5% Poor

0% Critical

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Optimal Technical Condition

Proactive Maintenance

Asset Planning

Operational Excellence

Safety and Reliability

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Nord Stream

NEL

OPAL

Gazela

4. Ongoing Projects - Nord Stream – OPAL / NEL – Gazelle A third Route of Russian gas to Europe

Nord Stream NEL OPAL Gazelle

PN [bar] 220 200 170

100 100 85

DN [mm] 1 200 1 200 1 400 1 400

Q [BCM/rok] 55 (2 x

27,5) 20 35 30 - 33

Pipeline Length [km] 2 x 1224 440 470 166

Commissioning [year]

1. 2011 2. 2012 2012 2011 2012

Expected Investment [mil €] 7 400 1 000 1 000 400

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Thank you for your attention