geir simensen honeywell hi-spec solutions norway
TRANSCRIPT
Geir Simensen
Honeywell Hi-Spec Solutions Norway
Process operations
Plant and equipment availability
The history of seeking profitability from plant performance has been heavily weighted toward process operations.
Equipment and plant availability performance has been the wild card in business performance.
Strategic Opportunity
Hi-Spec’s Unified Manufacturing Solutions
Our Purpose
To Help You Proactively Manage Your Assets At The Optimum Cost
With Internet Speed & Reach!With Internet Speed & Reach!
Industry Trends• Asset Trends
– assets must run longer (>3 years between turnarounds)– impact of asset failure can be very large
• Expertise Trends– downsizing and aging workforce has caused “skill gap” at
plant sites– technology is evolving faster than it can be adopted
• Work Practice Trends– Asset management is moving from reactive to proactive– Formal abnormal situation management is improving
operations effectiveness
A Look At Plant Operations
Daily Production
Day
s p
er Y
ear
95% 100%< 60%
A typical Production Profile for an Asset Intensive Facility for a calendar year. 95 days
62 days
23 days
79 days
47 days
30 days
16 days
8 days
5 days
Production Target set by Enterprise
Real Life Examples
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$33.5 M
02
46
810
1214
1618
280
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$38.5 M
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3.2%5.8%
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1503
$24.2M
24.2M
5.8%This plant had 5.8% in lost capacity!
This plant had $24.2M in lost capacity due to asset availability & incidents!
This plant lost $38.5M!
And this plant lost $33.5M!
Factors Affecting Plant Operations
Plant Operating Target
Plant Capacity Limit
Daily Production
Day
s p
er Y
ear
Operational Constraints
Planning Constraints
95% 100%< 60%
Plant Availability
Plant Incidents
Between 3-15% in Lost Capacity is attributed to asset un-availability and incidents
ProductionManagement
DCS/APC/ Optimization efforts
ManufacturingExecution
Scheduling & ERP
NEW EMPHASIS!!Asset
Management
Factors Affecting Plant Operations
Plant Capacity Limit
Daily Production
Day
s p
er Y
ear
Operational Constraints
Planning Constraints
95% 100%< 60%
Plant Availability
Plant Incidents
Get that 3-15% in Lost Capacity Back!!
How you manage the health of your assets
ABNORMALSITUATION RESOLUTION
ORIENTYou become “aware” of a
problem.
DECIDEYou determine the cause and decide
what to do about it.
ACTYou take action to fix or respond to
the problem.
IMPROVE
facilitates this work process
ORIENTYou become “aware” of a
problem.
DECIDEYou determine the cause and decide
what to do about it.
ACTYou take action to fix or respond to
the problem.
MAINTENANCERESPONSE
OPERATORRESPONSE
DECISIONSUPPORT
DIAGNOS-TICS
IMPROVE
ABNORMALSITUATION RESOLUTION
DiagnosticsScouts
•IntelliScout•TurboScout•Loop Scout•Valve Scout•Transmitter Scout•and more
CMMS
OPERATORTOOLS
DECISIONSUPPORT
DIAGNOS-TICS
ORIENT DECIDE ACT
DiagnosticsIntelliScout
•Detects asset specific problems before they occur–Rotating & Reciprocating Machinery
–Heat Exchangers–Pumps–Instrumentation
CMMS
OPERATORTOOLS
DECISIONSUPPORT
DIAGNOS-TICS
ORIENT DECIDE ACT
Principle of IntelliscoutPrinciple of Intelliscout
• Black box statistical model• Set of correlated variables, relationships
dependent on asset behaviour
Flow, Suction Pressure, Temp
Motor AmpsRPM (if variable)
Example - Motor Driven Pump
Discharge Pressure, Specific Gravity
IntelliscoutIntelliscout
• Model predicts expected asset behaviour when in good condition
• Compare predicted behaviour with actual behaviour– Use historian to read actual, write
predicted
• Early warning of change in performance
AlgorithmsAlgorithms
• Steady State model• Data clustering
– Training space, linear, non linear
• Principal Component Analysis– Technique to find the directions in
which a cloud of data points is stretched most
• Radial Basis Functions– Non linear functional approximation
IntelliscoutIntelliscout
• Trained on data set representing normal behaviour
• Analytical model may not be possible– Too complex– Under instrumented
Performance Monitoring & Optimisation
TurboScoutTurboScout
Our Technological Solutions
• Gas path analysis and component matching techniques to derive component fault indices
• Component matching techniques to minimise fuel consumption and hence exhaust emissions
• Larson - Miller creep methodology and component matching techniques to evaluate remaining life
• Principal of corresponding states for real gases
On-line Performance Monitoring
Plant PVGas turbines
Compressors
Scrubbers
Coolers
etc.
Steady-state checks
Gas turbines fault indices
Compressors fault indices
Scrubbers fault indices
Coolers fault indices
Database of fault indices
Fault indices, alarms and complimentary trends
Off-line Model Based Analysis
Model based analysis
Optimisation (fuel consumption)
Predictive maintenance
Production based maintenance
Optimisation (compressor wash)
Database of fault indices from On-line system
• Loop Scout performs automated data collection on plant regulatory control loops
• Data is transmitted via the internet to an automated analysis engine for quick response
• Analysis report quickly focuses scarce engineering and maintenance resources on real problems
• Improved regulatory control performance provides a strong foundation for higher level control and optimisation
Loop ScoutLoop Scout
• Continuous monitoring and tracking of transmitters
• Provides diagnostic information based on soft failures reported from the transmitter
• Notifies when transmitter has been replaced or moved
Transmitter ScoutMaintenance
Operators
DECISIONSUPPORT
DIAGNOS-TICS
ORIENT DECIDE ACT
Valve ScoutMaintenance
Operators
DECISIONSUPPORT
DIAGNOS-TICS
ORIENT DECIDE ACT
• A Predictive Maintenance Solution for All Control Valves … Even Analog.
• Provides diagnostic information based on stroke travel and cycle thresholds
• Reduced costs through predictive valve maintenance
• Support of expanded asset management capability
• Improved productivity of maintenance resources
What Tools Do You Use for Maintenance?What Tools Do You Use for Maintenance?
Excel Spreadsheets
Intelliscout
Loop Scout
Turbo ScoutManual Calculations
CalendarProcess Simulation
Computerized Maintenance Management System
Ultrasonic Noise Detection
Infrared ThermographyOil Analysis
Motor Current Analysis
Vibration Monitoring
Open Control Systems
Data Historians
MathCad
Integrated Decision Support
• Alert Manager – Receives Symptoms generated
by the scouts + all other sources like vibration monitoring etc.
– Presents user with asset-specific information to act on, complete with recommendations and automated responses.
– Notifies the field maintenance staff and directs them to possible reasons, solutions, and supporting documentation.
Maintenance
Operators
DECISIONSUPPORT
DIAGNOS-TICS
ORIENT DECIDE ACT
Integrated Decision Support
• All assets• All information for each
asset– Diagnostics– Documentation– Fault history
• Recommended actions• Provide access to asset
specific information• Integration to existing
systems– Control System– CMMS / Reliability tools
Structured Troubleshooting
Provides information for current or potential faults
Evaluation activities: Obtain current status of the symptoms key to isolating the fault.
Repair activities: Activity to repair a confirmed fault.
All symptoms defined for the asset.
Status of failures: “?” potential, “!” confirmed and “X” eliminated. Related symptoms shown on expansion.
Provide information for diagnosing current conditions.
Fault History for This Asset: Status and history of faults.
Faults for Assets of the Class Diagnosis: List of current and past faults for similar assets.
Fault files
xRequired evaluation
Evaluation done, nothing found
Symptom found to exist
xRequired evaluation
Evaluation done, nothing found
Symptom found to exist
Simple Configuration•Diagnostic Builder
–Create Asset Types
–Build Symptoms
–Build Faults
–Build Symptom & Fault Trees
–Configure the symptom & fault notifications E-Mail, Pager
User Alert
Work Order
Maintenance Management
CMMS
OPERATORTOOLS
DECISIONSUPPORT
DIAGNOS-TICS
ORIENT DECIDE ACT• Available via our Partners
• Fully integrated with Decision Support
• Work orders triggered automatically
Flash Gas Compressor, throughput $290K day
Cooler Fouled
Gas too hot,Volume larger
Compressor couldnot maintain flow
Compressor movestoward surge
due to lack of flow
Compressor startsto recycle gas
Fuel consumptionincreased
Excess turbinecreep life
consumed
Benefit - Higher Availability
EXAMPLE: Higher Availability Through: • Early Awareness, • Effective Troubleshooting, • Efficient Resolution
Scenario…
• No symptoms detected
• Display of controllers, valves and transmitters indicate normal
ABNORMALSITUATION RESOLUTION
ORIENTYou become “aware” of a
problem.
DECIDEYou determine the cause and decide
what to do about it.
ACTYou take action to fix or respond to
the problem.
IMPROVE
IMPROVE
Orient
• Valve Scout detects a variation in the travel profile of 77FV211
• Alert Manager automatically executes a Loop Scout Detail on 77FC211
• Recommended action : Run Loop Scout Expert.
Decide
• Loop Scout Expert confirms valve stiction and discounts poor tuning
Act
• Alert Manager automatically generates the Work Order for valve maintenance on 77FV211.
Forventede muligheter med Alert Manager for Statoil Kvitebjørn (1 av
2)• Sikre/forbedre regularitet– Tidlig feildeteksjon, “Alert” via e-mail / SMS– Operatørstøtte for rask konsis feilhåndtering
• Avlasting av personell på plattformen– Kontinuerlig overvåking av mange utstyrskategorier automatisert– Standardisering av arbeidsrutiner og fokus på arbeidsprosesser– Enkel tilgang til all informasjon (prosedyrer, manualer,
leverandørinformasjon etc.) – Intergrering av all tilstandsovervåking
• Forenklede / ferdigutfyllte arbeidsordre / notifikasjoner• Delvis automatsk tolking av resultater• Automatisk genererte funkjsonstester og rapporter
Forventede muligheter med Alert Manager for Statoil Kvitebjørn (2 av
2)• Samle og systematisere erfaringsdata og feilhistorikk
– Forenkler feilsøking og er grunnlag for analyse av tilltak• Forenkler deling av oppgaver mellom landbasert personell og plattform
– Landpersonell utfører tilstandsoppfølging og utsetdelse av arbeidsordre
– Automatisk varsling til landbasert personell fra AM• Forenkler deling av oppgaver i et multidisiplint team• Bevisstgjøring av teknisk tilstand
– Stimulere til målstyring– Styring av vedlikeholdsprogram– Reduksjon i forebyggende vedlikeholdsaktiviteter