condition & performance monitoring proactive maintenance ... 08 final.pdf · reactive to...

Condition & Performance Monitoring Proactive Maintenance of Subsea Installations

Ingvar Koppervik

Presentation lay-out

1. Subsea development– past and current state of the art

2. Predictive & proactive maintenance– new operation philosophy

3. Subsea installation monitoring technology– novice to intelligent

4. Preventive maintenance in practice– AI Card failure in a Subsea Control Module

5. Summary– CPM main advantages

3

Subsea Development

FPSOTLP

Light WellIntervention

GuidelinelessDeepwater Trees

Subsea ManifoldSmart Well

Control Systems Subsea TemplateSystems

Standard SubseaTrees

ROV & Tie-In Systems

Subsea Processing

MSVFixed

Platform

Reactive to Proactive Maintenance

• Increased maintenance costs • Harsh environments• Inaccessible environments• Environmentally sensitive areas• HSE• Integrated Operations

Reactive to Proactive Maintenance

Proactive

Planned

Reactive

Don’t fix Single sensortrending

KPI trending

TCI trending

Collaboration

Novice to intelligent

Ope

ratio

nal e

xcel

lenc

e

6

Enabling Technology,Technical Condition Index (TCI)

• TCI takes KPI (Key Performance Indicators) several steps further– TCI takes in the complete picture

– TCI build expert knowledge into the system

– TCI summarize knowledge about plant integrity by aggregation from the bottom up

• Focus on trends in development (early detection), not transients

• Developed in a joint industry project between 1996 and 1999

• Early users: Shipping, and Troll Kollsnes gas refinery since 2000

9

Proactive Maintenance in Practice: AI Card failure in a Subsea Control Module

1010

101000

10

AI card electrical component failure making all SEM A internal Hydraulic sensors go from valid readings to zero.

AI card electrical component failure making all SEM A internal Hydraulic sensors go from valid readings to zero.

1111

101

11

SEM ASEM A

SEM BSEM B

12

SensorIntegritySensor

Integrity

ValveOperation Log

ValveOperation Log

HydraulicSystem

HydraulicSystem

Electrical & Comm. System

Electrical & Comm. System

Choke Integrity

Choke Integrity

MPFMMPFM

......

Data BaseData Base

Gas Compression

Gas Compression

MP PumpsMP Pumps TCI GeneratorTCI Generator

Information/Knowledge

Server

Information/Knowledge

Server

Subsea DataSubsea Data

People

TechnologyProcesses

Integ

rated

OperationsLife Of Field

CPM added value

• Early detection of failure and degradation– Decreased downtime/increased utilization

– Proactive, condition based maintenance

– Better planning of scheduled maintenance

• Faster turnaround in troubleshooting– Complete historian database

– Tools for collaboration and data sharing

• Address demographics and “brain drain”– Encapsulate expert knowledge in the system

• Improved HSE records– Detect hydrocarbon and chemical leakage

– Safer operations

– Move people from offshore to onshore