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Integrated Operations - Parallels between Oil & Gas and Shipping
Harald Sleire
MARINTEKDepartment of Maintenance Technology
Trondheim, Norway
Recent developments in Oil & Gas industrycollaborative decision making in Operation andMaintenance
Predicting the way forward in Ship Operation and
Maintenance
Bulkforum; May 12th 2009 - Bergen.
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OutlineOutline
Condition-based maintenance why?
Oil & Gas industry challenges and constraints
Integrated Operations / E-Field / Smart-Field- a convenient, high-profile enabler for improved maintenance
Center for Integrated Operations in the Petroleum Industry- a research initiative in Norway (CRI*)
Condition monitoring on static equipment- Separators, Heat exchangers, Safety critical valves, Chokes
Summary; Oil & Gas
Shipping industry challenges and constraints
Shipping; Collaboration & Remote support - TOCC
Data communication, Technical Condition Indexing
Summary; Shipping
CRI Centre for Research-based Innovation
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Oil & Gas facilitiesOil & Gas facilitiesChallenges & constraints :
Physical isolationCommunication
Weather / seasons
Reliable condition monitoring data
Data analysis and trending capability
Maintenance not optimised
Optimising production and overall recovery
Maximising production availability
Monitoring and KPIs for continual improvement
Up-turn in business
Shortage of experienced competent staff
Age profile of staff
HSE
Corporate imageProfit
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Oil & Gas; Operation & MaintenanceOil & Gas; Operation & Maintenance
As is (As is ( and may become worseand may become worse ))
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MaintenanceMaintenance
Safety/integrity
Availability
Integrity
Availability
Safety/integrity
Availability
Too much of theright maintenance
Continue with thesame amount of thewrong maintenance
Too little of the rightmaintenance
Maintenance Optimization
Critically assess Maintenance
Condition based maintenance
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Why increase ConditionWhy increase Condition --based Maintenance in oilbased Maintenance in oiland gas industry?and gas industry?
Unnecessary maintenance leads to decreased regularity andincreased maintenance costs
Lack of knowledge about the technical condition of thecomponents can make the maintenance period longer than planned
~50% of personnel injuries offshore occur in connection with
maintenance (Petroleum Safety Authority Norway)
To increase the knowledge about the failure mechanisms andprediction of remaining lifetime
Early Fault Detection systems are dependent on reliable sensor datafrom condition monitoring
Other onshore industries have good experience with condition basedmaintenance
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Integrated Operations / EIntegrated Operations / E --field / Smartfield / Smart --fieldfield-- a convenient higha convenient high --profile enabler for improved maintenanceprofile enabler for improved maintenance
covers much more than just operations
To facilitate :- communication of information- between people and organisations (geographically spread)- shared situational awareness
in order to achieve better, faster decisions .
It involves :Man (People), Technology & Organisation (MTO)
Applicable to :Oil and Gas, Medicine, Shipping, and much more .
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Centre for Integrated Operations in theCentre for Integrated Operations in thePetroleum IndustryPetroleum Industry www.ntnu.no/iocenterwww.ntnu.no/iocenter
NTNUSINTEF
IFE
OilCompanies
Suppliers
Conducts research, innovation and education
within the IO field, to promote acceleratedproduction, increased oil recovery,reduced operating costs and enhancedsafety and environmental standards.
CRI Centre for Research-based Innovation
PROGRAM 1Drilling and well construction
PROGRAM 2:Reservoir management and production optimization
PROGRAM 3:Operation and maintenance
PROGRAM 4:Integration across disciplines
http://www.ntnu.no/iocenterhttp://www.ntnu.no/iocenterhttp://www.ntnu.no/iocenter -
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Data processing
Sensor technologyand automation
Visualization
Geographicallydispersed teams
Wearablecomputing
Smarterdecisions
RESEARCH CHALLENGES FOR INTEGRATED OPERATIONSRESEARCH CHALLENGES FOR INTEGRATED OPERATIONS
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Condition Monitoring on Static EquipmentCondition Monitoring on Static Equipment
The situation today:
The technical condition of static equipment is not monitored in thesame way as for pumps and compressors
Much information from the monitoring systems is not used
The reliability of instrumentation & signals is questionable
Time-based (RBI) insp & maintenance during shutdowns
Equipment types which warrant focus:
Separators
Heat exchangers
Safety critical valves and chokes
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Failure detection methods on staticFailure detection methods on staticOil & GasOil & Gas equipment offshoreequipment offshore
Detection Method % contribution to detection of
failureCasual observation/ unknown 60-65 %
Periodic preventive maintenance 10-15%
Continuous condition monitoring 10-15%
Inspection 5%
Other (production interference, ondemand, functional testing etc.)
5-10%
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Safety Critical Valves; test rig
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Separators; phase I laboratory set-upLuft tilfrsel 7 bar
1 atm.
til data logger
til data logger
P
P
0-40m3/time max. 40m3 og 2 bar (4kW)
separator
Luft tilfrsel 7 bar
1 atm.
til data logger
til data logger
PP
PP
0-40m3/time max. 40m3 og 2 bar (4kW)
separator
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Oil & Gas facilities: Operation & Maintenance
Overcoming some challenges & constraints :Physical isolation
Communication
Weather / seasons
Reliable condition monitoring data
Data analysis and trending capability
Maintenance not optimised
Optimising production and overall recovery
Maximising production availability
Monitoring and KPIs for continual improvement
Up-turn in businessShortage of experienced competent staff
Age profile of staff
HSE
Corporate image
Vendor: rotating machines
Subsurface team: reservoir
Production / Maint team
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SummarySummary Oil & GasOil & Gas
Failure detection should be dominated by continuous or periodic conditionmonitoring, and not casual observations by personnel
Required Technology is available (and used on exception basis), but often still
not specified in Philosophies / Tenders as required by company
Man and Organisation aspects are at least as challenging as Technology
Condition-based predictive maintenance must be promoted to decrease thenumber & frequency of shutdowns and increase the efficiency and lifetime ofthe equipment
Data sharing & and remote decision support will lead to
Increased safety & integrity
Increased life time of the equipment
Increased process regularity
decreased maintenance costs
The costs due to periodic shutdown and/or decreased efficiency should be
emphasised and highlighted
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Shipping: Operation & MaintenanceChallenges & constraints :
Physical isolationCommunication
Weather / seasons
Reliable condition monitoring data
Data analysis and trending capability
Maintenance not optimised
Optimise operational efficiency & fuel
Maximise time at sea / Minimise off-hire
Monitoring and KPIs for continuous improvement
Fluctuation in business
Shortage of experienced competent staff
Age profile of staff
Health, Safety & Environmental impact
Corporate imageProfit
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Improve competence and tools for utilisation of technicaloperational data in the maritime industry
An example of collaboration in shipping
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Data communication:
Fibre optic cable? Oil & Gas; real-time data in real time
Satellite communication? Automatic data transmission as required
Satellite communication? Periodic e-mail with .xml data files
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TOCC project
OFFICE
SHIP
Feedback
Registration
Main engine performance
Auxiliary engine performance
Hull and propeller performance
Infrastructure
Support
User meetings
Management
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Indexing fleet performance
Alarm
Alert
OK
S h i p
S
u p e r i n
t e n d
e n
t
F l e e
t M g r . Technical performance
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TOCC procedureImplementing Performance Measurement in the organisation
Develop formsInput ship static dataSend forms to ship
Install formsInput measure dataForm validate dataData sent to TOCC
Receive xml/emailValidate dataStore dataAnalyze dataGenerate reportSend report to shipSend report to office
Receives reportMaintenance
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Keys to success
Selection and maintenance of instrumentation
Procedures for performance measurement
Quality control of practise versus procedures
Feedback and corrective actions to users/reporters
Follow-up of deviations responsibility and support
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TOCC examples
Improvement at fleet level
Improvement at detail level where corrective action can berecognised
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Fleet with less than 10 vessels
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Fleet with approx. 20 vessels
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Ideal value
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Ideal value
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SummarySummary ShippingShipping
Many of the Shipping challenges are similar to those in Oil & Gas
The justification is apparent for a trend towards:
Remote monitoring, shared awareness, decision support, KPIs
Shipping is more standardised than offshore, and may benefit more from operations supportcentre
Failure detection should be dominated by continuous or periodic condition monitoring,and not casual observations by personnel
Required Technology is available (and used on exception basis), but often still notspecified in Philosophies / Tenders as required by company
Man and Organisation aspects are at least as challenging as Technology
Condition-based predictive maintenance must be promoted to decrease the number &frequency of shutdowns and increase the efficiency and lifetime of the equipment
Data sharing & and remote decision support will lead to
Increased safety & integrity
Increased life time of the equipment
Increased process regularity ( Maximise time at sea / Minimise off-hire)
decreased maintenance costs
The costs due to periodic shutdown and/or decreased efficiency should be emphasisedand highlighted