peter stock, executive director, sentratech, seattle ... · pdf file~moubray, rcm ii (1992)...

Peter Stock, Executive Director, Sentratech, Seattle,

Washington, USA

22-24 November 2010, Johannesburg

THE ALASKA EXPERIENCE

RELIABILITY CENTRED

MAINTENANCE AND

ONLINE MONITORING USING THE PI SYSTEM

22-24 November 2010, Johannesburg

ABOUT ALYESKA PIPELINE

• 800 miles long

• 48” diameter pipe

• 5 Pump Stations

• Marine Terminal

• 1.4 Million bpd operating

capacity

• Logistics & Operations

centers in Valdez,

Anchorage, and Fairbanks

Brooks Range

Tanana River Bridge Crossing

Valdez Terminal

22-24 November 2010, Johannesburg

Operation Control Center

Background

• Currently running 42 turbines within 6 pump stations

• Pipeline throughput drops from 2.136 million bbpd to

1.1 million bbpd

• High cost of transporting Alaskan crude

• Advances in engineering design

• 2001 Alyeska embarked on a Strategic

Reconfiguration (SR) project

Strategic Reconfiguration (SR)

• Primarily involved electrifying and automating the pump

stations

• Power source at each pump station was changed to

generated power or commercial power

• Project included upgrading all control systems using

PLCs across the pipeline

• SR project reduced the number of turbines to 10 and

the number of active pump stations to 4

Right-of-Way Agreement (ROW)

• Pipeline crosses Federal and State land

• Agreement stipulates that “all physical assets used on

the ROW must a have a maintenance program in place

before the assets are put into service”

• Sentratech invited by Alyeska to develop the

maintenance strategies for all the reconfigure assets

using Reliability Centered Maintenance

RCM – What is it?

Reliability-Centered Maintenance is a process used to

determine what must be done to ensure that any physical

asset continues to do what its users expect in its present

operating context. ~Moubray, RCM II (1992)

� Describe functions, failure modes, causes, effects and

consequences

� Measure Performance, Actuarial Analysis, Failure Data

� Determine appropriate preventative & predictive tasks for

each physical asset

Evolution of Maintenance Strategies

Effectiveness

Efficiency

Reactive

“Break-Fix”

Run-to-failure

Reactive

“Break-Fix”

Run-to-failure

Preventative

Calendar-based

Runtime-based

Preventative

Calendar-based

Runtime-based

Predictive

Model-Based

Learning Systems

Predictive

Model-Based

Learning Systems

22-24 November 2010, Johannesburg

Maintenance Strategy Initiatives

• Mission

� Ensure pipeline reliability and integrity

using advanced maintenance strategies

• Goals

� Proactive vs. reactive maintenance

� Optimize available resources

� Discover new & better ways to operate

• Challenges

� Difficult operating environment

� Complexities of modernization

� Attrition of SME’s

� Pressure to reduce operating costs

� Increasing scrutiny and regulation

Systems Analyzed

• Safety integrity pressure protection system (SIPPS)

• Booster pump building

• Manifold building

• Fuel systems

• Crude pressure relief systems

• Siemens turbo generators

• Commercial power supply

• 2.25 MW standby generators

• Control module

• Mainline pump set

• Remote gate valves (RGVs)

March 7 – 10, 2009 San Diego, CA, USA

Remote Gate Valves (RGVs)

SCADA

PI

Smart Signal

EQUIPMENT DIAGNOSTICS AND

RESOURCE CENTER (EDRC)

Discrete

Maintenance

Alarms

Reactive

Discrete

Maintenance

Alarms

Reactive

AF/ACE Calculated

Alarms

Condition-Based

Monitoring

AF/ACE Calculated

Alarms

Condition-Based

Monitoring

ACE/AF Calculated

Events

Condition-Based

Monitoring

ACE/AF Calculated

Events

Condition-Based

Monitoring

Maintenance NetworkSCADA Network

Equipment

Warnings

Predictive

Equipment

Warnings

Predictive

Automated PM

Completion

Work OrderScheduling

WORK MANAGEMENT

CorrectiveWork

Orders

All Asset

Backlog

Preventative

All Asset

Backlog

Preventative

Operational

Instrument

Data

Operational

Instrument

Data

High Resolution

Instrument

Data

High Resolution

Instrument

Data

Maintenance Strategies in Action

RESULTS

The EDRC has demonstrated tremendous value:

� Centralized access to equipment and system diagnostics

� Automating 200+ Calendar/Runtime-based PMs

� Facilitating new Condition-Based Monitoring (CBM) algorithms

� Providing post mortem and root cause analysis on equipment failures

� Communicating initial equipment diagnostics with Operations Engineering, OCC,

Field Maintenance, and other SMEs

� Assisting field maintenance with troubleshooting and validating corrective actions

taken in the field

� Reducing intrusive maintenance impacts

� Preventing unintended shutdowns and equipment outages

TANGIBLE BENEFITSEDRC BENEFIT ANNUAL

SAVINGS

Regulatory Calendar-based PM Automation

DOT Valve Strokes – Reduced Field Man-Hours $400,000

Function Testing of Valves – Reduced Field Man-Hours $100,000

DOT Relief Valve Testing $50,000

Tank Level PM’s $35,000

Continuous CBM and PBM Algorithms

Unplanned Downtime Avoidance $350,000

Device Deviation Monitoring – Reduced Field Man Hrs $150,000

FIRST YEAR ANNUAL SAVINGS $1,085,000

22-24 November 2010, Johannesburg

Questions ??

Peter StockP.O. Box 11754

Bainbridge Island, Washington 98110

USA

+ 27 829233646

peter.stock@sentratech.com