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DNV GL © 2016

Confidential

10 October 2016 SAFER, SMARTER, GREENER DNV GL © 2016

Partha Sharma & Aravind Nair

2nd November 2016

Confidential

Application of Sensor Technology and Advanced Analytics

1

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10 October 2016 2

Pipeline System Integrity

The function of submarine pipeline systems is to efficiently and safely transport a variety of fluids

Pipeline system integrity is defined as the pipeline system’s ability to operate safely and withstand the loads imposed during the pipeline lifecycle. If a system loses this ability, a failure has occurred.

LEAKS RUPTURE COLLAPSE

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10 October 2016

Why Manage Pipeline / Riser Integrity ?

Ekofisk A, 1 Nov 75. Ignited 10” flowline rupture at 1m

above sea level. 3 fatalities out of 71 on the platform due

to lifeboat accident during evacuation.

Piper Alpha, 6 July 88. 4 risers ruptured and ignited at

cellar deck level. 167 fatalities (including 2 rescuers) out

of 226 on the platform, mainly due to being trapped in the

accommodation by smoke.

South Pass 60 B, 19 Mar 89. Ignited large gas release

from open depressurized 18” riser, 5m above sea level. 2

fatalities out of 8 on work barge. 5 fatalities out of 13 on

Platform B, due to fire or drowning during escape.

Glider Field, 12 May 2016. Recent pipeline leak,

considered medium size spill with estimated 88,000

gallons of oil released into the Gulf of Mexico. Cause of

leak under investigation.

Piper Alpha 1988

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10 October 2016

Typical Elements of IM System

Company Policy

Organizational & Personnel

Reporting and Communication

Operational control and Procedures

Management of Change

Contingency Plans

Audit and Review

Information Management

4

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10 October 2016

5

The Integrity Management Process

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10 October 2016 6

Anchor

6 %

Impact

7 %

Corrosion

40 %

Structural

8 %

Material

4 %

Other

18 %Nat. Hazard

17 %Anchor

18 %

Impact

24 %

Corrosion

27 %

Structural

5 %

Material

10 %

Other

11 %

Nat. Hazard

5 %

Why do pipelines fail?

The North Sea*

* Fittings are not included The Gulf of Mexico

All Incidents reported in the North Sea and the Gulf of Mexico with and without leakage

Sources: DNV GL Internal database and PARLOC 2001 HSE

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10 October 2016

Corrosion Related Failures

– Ageing pipeline

– coating breakdown

– CP system not functional

– Under deposit corrosion

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– Fluids • HP/HT, Sour fluids

• Microbial Corrosion

• Change from Design

Sources: DNV GL Internal database and PARLOC 2001 HSE

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10 October 2016

Same Problem, different people, different concerns, different needs!!

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Integrity Manager

Integrity budget and

schedule

Manage overall planning

and scheduling

Access to engineers work,

oversee progress, and

approve

Regulator

Outstanding high risk

items,

compliance

Oversight of all systems

and high risk areas

Integrity Engineer

Operational condition

and risk of the pipelines,

risers and wells

Minimize operational costs,

while achieving high level

of integrity and system

reliability

Operations Manager

Integrity activities’

impact operations

Easy to do risk

assessment, analyze

survey results, perform

calculations and propose

activities

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10 October 2016

Information Management

Data & Documents

– Large quantity of data requires tools for

– Asset Register

– Carrying out Assessment

– Link to other systems

– Planning activities

– Storing data

Increases efficiency

Enables transparency in decisions

Visual representation of key data

Access from multiple dept./locations

9

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10 October 2016

Synergi Platform

10

Geographic Information System

(GIS)

ERP

Inspection Results

Calculation tools (Excel, VB, Access..)

Documents (formats/ file

drives

Synergi Platform

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10 October 2016

Instant overview; see the risks and what to do

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10 October 2016

Lifetime Risk Overview and Trends for The Asset

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10 October 2016

Pipeline Health Monitoring

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Sensors

• Strain Gauge • Accelerometer • Fiber Optics Sensor • AE Sensor • Erosion Sensor • Corrosion Sensor

Physical Inspections

• ILI • CP Survey • Coating breakdown/

Disbondment • Mechanical Damage

Models

• Probabilistic Risk Model • FEA Model • Corrosion Model • CFD Model

Asset Data

• Metocean • Operational • Structural

Decision Board

• Repair Solutions

• Damage Estimate

• Cost Estimate

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10 October 2016

Sensors

Long term monitoring Dual chamber arrangement (HP & 1ATM)

EB welded titanium construction

Design life, more than 30 years

Qualified solution (same enclosure as ASD & APD)

Single or Dual purpose (ASVD or APVD)

Short term inspection • Single chamber enclosure

• Lightweight and rapid deployment

• On the “shelf” for quick delivery

• Stand alone

• No integration

• No bandwidth restriction

SOURCE

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10 October 2016

Advanced Numerical Models

15

Flowline Thermal Buckling Component FEA

Erosion / Corrosion Model Vibration(VIV and FIV)

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Simulate, Monitor and Operate

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Subsea Integrity

SIMULATE

High Performance Computing

Advanced Predictive Analytics coupled with Sensor technology- from Design to Operation support

OPERATE

Integrity-Compliance

Safety

Regulation

Fitness for

Service

Cost

Sensors Network

MONITOR

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10 October 2016

Summary

Pipelines fail because:

– Ageing system

– Insufficient data to assess status

– Poor understanding of systems

– Pushing the limits of technology

– Lack of experienced resources

Benefits of Sensor & Analytics Based IM system :

– Continuous monitoring system instead of spot measurements

– Develop trends over time to understand unknown loading conditions

– Information can be used to prioritize inspection locations and frequency

– Operational cost reduction due to reduction in inspection campaigns

– Provide technical assurance to regulatory bodies by demonstrating adequate remaining life of existing assets

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10 October 2016

People & the environment: A mutual support system to coexist

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10 October 2016

10 November, 2016 Private and confidential

19

Probability of Failure

Cu

sto

mer I

mp

act

Ensuring security of supply & meeting customer demand

2 1

25

20 10 3

40 20 5 1

100 5

Delivering oil/gas/energy to consumers - efficiently, reliably, safely and with care for the environment

En

vir

on

men

t Im

pact

Peop

le &

Prop

erty

Im

pact

Bu

sin

ess I

mp

act

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10 October 2016

O&G industry ecosystem

20

O&G production, processing and transportation

ecosystem

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10 October 2016

O&G industry ecosystem

21

O&G production, processing and transportation

ecosystem

Structure Ecosystem

Ship Ecosystem Plant Ecosystem

Pipeline

Ecosystem

“People” Ecosystem¹

“Environment”

Ecosystem¹

Note 1: We leverage the interaction of these ecosystems with the asset ecosystems, we do not manage the “internals” of these ecosystems. This interaction will be primarily

managed via Synergi Life QHSE and incident management

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10 October 2016

Complex interdependencies in how we do business

Information rich throughout all operations

High dependency on the movement of information

Each “operational task” only as effective as the quality of the data

Pip

elin

e p

ro

cess a

nd

in

form

ati

on

inte

rd

ep

en

den

ce

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10 October 2016

Maturity in managing operational risk and performance

Elements of Operational Risk Management

Stakeholders Societal Impact

Environmental Impact

Asset Performance

Business Performance

Chaos! Run to fail! Paper Records! No consistent business processes

Operating area or business areas individually get consistent processes and technology

Initiatives and processes at a corporate/enterprise level, enterprise technology

Data and information driven analytics in and across all operations

Disaster waiting to

happen

Localized Processes

Enterprise Management

Optimized

Enterprise

Desig

n &

Constr

uction

Opera

tional

Pla

nnin

g

Inte

grity

& R

isk

Com

pliance

Managem

ent

Main

tenance &

Pla

nnin

g

Contr

ol Room

Opera

tions

Opera

tional M

atu

rity

Level

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10 October 2016

Breaking down the barriers to success

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Optimized

Enterprise Data and information driven analytics in and across all operations

Desig

n &

Constr

uction

Opera

tional

Pla

nnin

g

Inte

grity

& R

isk

Com

pliance

Managem

ent

Main

tenance &

Pla

nnin

g

Contr

ol Room

Opera

tions

Design & Construction

Operational Planning

Integrity & Risk

Compliance Management

Maintenance & Planning

Control Room

Operations

Elements of Operational Risk Management

Stakeholders Societal Impact

Environmental Impact

Asset Performance

Business Performance

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10 October 2016

Are we engineers or data technicians? - The Path Forward

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NOW FUTURE

Need to drive cost savings through structured use of common data across disciplines, reducing down time, reducing

risk and strengthening operational decisions

80% or more

Gathering and

Organizing Data

20% or less

Analyzing and creating business

value from data

20% or less

Gathering and

Organizing Data

80% or more!

Analyzing and creating business

value from data

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10 October 2016

Current pipeline products

Synergi Gas

Synergi Water

Synergi Pipeline

Safeti/Phast

Sesam Pipeline

Synergi Pipeline Simulator (SPS)

SPS – OQ, Training & Leak Detection


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Functional/Domain oriented

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10 October 2016

Next generation pipeline solutions

Feasibility & Design

Construction Traceability

Maintenance & Planning

Regulatory Tracking

Operational Planning

Safety & Integrity

Emergency Planning & Response

Synergi Pipeline

Synergi Gas

Pipeline Simulator

Synergi Water Safeti Phast

Sesam Pipeline RAM

Busin

ess A

rea S

olu

tions

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10 October 2016

Process Safety, Risk &

Reliability

Design & Engineering

Maritime & Class

Electric Grid Reliability

Simulation & Optimization

Asset Integrity & Performance

Plant X X X

Pipeline* X X X X

Structure X X X

Ship X X X

Electric Grid X X

QHSE

An asset centric mind set

Note: * Pipeline includes gas and water networks

Delivering an ecosystem of asset centric applications and business area solutions

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Improving flexibility to deliver customer centric solutions

Pan Asset Intelligence Asset Ecosystem Business Area Solution Applications

The ecosystem concept will allow DNV GL to

Provide out-of-the-box products in the form of preconfigural solutions

Delivered on premise or as cloud based solutions

Deploy solutions deeply embedded in the enterprise operations of our customers

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Delivering added value: Towards configurable business solutions

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Synergi Pipeline

Synergi Pipeline

Simulator

Safeti

Phast

Sesam Pipeline

Maros,. Taro (RAM)

Synergi Gas

Synergi Water

Synergi Gas

Each product has a set of applications and

analytical “engines”

Cloud based analysis services

and applications

Configured Cloud/on premise

business solutions

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10 October 2016

Digital pipeline eco-system - An open and shared platform

Harvesting

environment data (weather, population …)

Harvesting

sensor data Harvesting

SCADA

Operational

Planning

Integrity, Risk & Compliance Management

Operator Training and Qualification

Leak Detection

Pipeline Design

& Route selection

Barrier Management

Business Analytics

Harvesting

inspection data

Digital

Asset

Custodian

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10 October 2016

The digital twin

10 November 2016 Private and confidential

32

Physical

Asset

Operational Data

Operational

Demand

As built + revisions

How the asset works

The current & prior state of the asset

The projected demand on the asset

The musculoskeletal system

The central nervous system

and autonomous system

Medical records and

personal history

What do we need to be fit

for?

DNV GL Analytics engine

Advanced analytics, including ML

What the asset is fit for

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The changing composition of the digital twin

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Private and confidential

33

Operational Data

Operational

Behavior

Operational data volumes are getting higher and will tell us in more detail about more attributes of the asset state and its performance

Customer demand is for more and better predictive analytics.

Increasingly sensor data will tell us more of the current state from direct readings, reducing the effort needed for accurate current state assessment based upon sparse data

Increasingly operational behavior will be defined or validated by empirical data rather than modeling on sparse data

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10 October 2016

Adding value to pipeline analytics

ICDA/Internal corrosion

Security of supply

QRA and advanced consequence modelling

SCC detection (SCCDA) & Fatigue and pressure cycling

Risk based route determination – hydraulic efficiency and integrity/HCA/consequences, structural integrity

(offshore)

Hydrotest planning

Offshore pipeline design

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10 October 2016

Current Product Lines Analytical and Information

Services

Internal corrosion & ICDA

Hydraulic Modeling

ICDA Process

Corrosion Prediction

SCADA

Process Safety, Risk & Reliability

Maritime & Class





QHSE Procedures/Incidents

Internal Corrosion

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Services

State of the art QRA and advanced consequence models

Interactive consequence analysis and defect analytics

Phast: impact

contours

Defect Assessment

Risk Analysis


Maritime & Class






Pipeline Integrity

Operational State and

Planning

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10 October 2016


Services

Security of supply – meeting customer demand

A planning or real time operational risk solution

for Pipelines and gas distribution networks

Area Isolation

RCM (compressors)

Probability of failure

SCADA


Maritime & Class






Security of Supply

Customer

Management

Contingency planning

Mains Replacement

Planning

Maros (RAM)

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Plant Ecosystem: Predictive analytics using RAM in operations


39

Integrity Management

RAM Analysis

RAM Analysis

Predictive Analytics

Integrity management

plans, inspection

schedule, asset

properties

Inspection results,

failures, risk levels,

remaining life

FEED & Detailed

Engineering

Design

Operations

Inspection results,

failures, remaining life,

operational processes

Predicted performance

current and alternatives,

Critical equipment

Actionable insights

RAM Compute

KPI Dashboards

Asset Centric

Digital Twin

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10 October 2016

Another way of putting it…

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Safer Reducing major incidents which impact people, property and the environment

Smarter Making more timely risk based operational decisions from accurate information

Greener Improving energy efficiency and reducing environmental impact from incidents

We MUST become:

Data and

information

driven analytics

in and across

all operations

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10 October 2016

SAFER, SMARTER, GREENER

www.dnvgl.com

Digital asset ecosystems!

41

[email protected]

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10 October 2016

Pipeline: Solution overview of proposed MVP


43

Prioritized Sites

People Impact

Customer Impact

Chance of failure

Proposed excavation site

Pipeline or Gas Network operator

Software subscription

service to assess risk of

1-call ticket

• Customer Impact:

Synergi Gas

• People Impact: Phast

• Likelihood of pipe failure:

Synergi Pipeline

Contractor raises

“ticket” with call

centre

Asset owner

notified

Excavation site support

prioritized to reduce

possible impact to people

and customer supply

DNV GL Customer

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Increasing safety and reducing customer impact using risk based excavation monitoring


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Significant increase in

risk at excavation site

Exposure: Concentration by distance

125 customers

potentially impacted

Residential area central

to fire/explosion zones

Proposed dig location

Risk based assessment to help reduce the single largest cause of serious

incidents in gas networks that lead to fatalities and injuries.

• 1,000+ enquiries per day per company

• Average cost to operator is $350,000 per incident

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DNV GL’s Plant Ecosystem

Integrating data and analytics for predictive analysis to drive operational excellence

45

Compare Baseline

performance with Forecast

using observed equipment

failure rates

Identify Critical Equipment

Evaluate losses

Identify solutions with positive

ROI

Change in contribution to

losses from compressors

Change in ROI from

observed failures against

design Impact / Opportunity of $3M

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10 October 2016

Internal corrosion & ICDA

NACE ICDA

O&G Journal March 2013 …”The ideal solution should incorporate four broad technologies: multiphase flow modeling, corrosion prediction, use of current ICDA (internal direct assessment) methodology and real-time corrosion monitoring. These types of technologies are capable of not only determining propensity for water retention, but also the “corrosivity” of the environment in the presence of the aqueous medium for the identified critical segment.”

Dry Gas Wet Gas

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Security of supply – meeting customer demand

Customer impact is a

major consequence concern

Condition and reliability can be

combined with customer impact

to improve business decisions

– Operational planning

– Integrity planning

– Replacement planning

Consequence of a pipe failure, loss/drop of supply

or compressor failure/limitation

Number of impacted customers by Domestic, Industrial,

Commercial, power plant

Total and %age of expected gas demand not met

Pipeline failure or shutdown

Loss of supply source

Loss/limitation of a compressor

Synergi Gas modules Area Isolation and Customer

Management can provide this information

Gathering System

Distribution

network

Supply: Source/Production

Demand: City, Power plant,

industrial, commercial

Compressor station

Isolation valve

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10 October 2016

State of the art QRA and advanced consequence models

Synergi Pipeline

Click on a pipeline feature:

• Girth weld

• Defect - corrosion, crack etc

• One call ticket location

Details

Consequence contours

B31G

CorLas

…..

Feature context menu

of options

Phast as a service

service

Run Phast calculations on

selected pipeline location

Trigger analysis request:

Location and analysis input made available to Phast service

Display results back in

Synergi Pipeline

Synergi

Pipeline

Results published to

information service

Accessible by Synergi Pipeline

Advanced consequence

modelling

Defect assessment support

Compare to HCA

Finding “hot spots” of very

high impact

Detailed evaluation of

identified sites