holistic coordinated optimisation for shipping€¦ · a pre-project proposal oil & gas...
TRANSCRIPT
1
Holistic Coordinated Optimisation for Shipping
Andrew [email protected]
MARINTEKResearch Director
Department of Maintenance TechnologyTrondheim, Norway
Predicting the way forward in Ship Operation
A pre-project proposal
MARINTEK Seminar at NorShipping; 10 June 2009.
2
Outline: other industries c.f. shipping; -
a pre-project proposal
Oil & Gas industry challenges and constraints
Integrated Operations / E-Field / Smart-Field
Center
for Integrated Operations in the Petroleum Industry
Summary; Oil & Gas
Shipping industry challenges and constraints
Management, monitoring & improvement principles
Examples from other industries
Shipping; Collaboration & Remote support -
TOCC
Summary; Shipping
Holistic Coordinated Optimisation for Shipping;
Research Pre-project proposal
After the Research Pre-project
3
Oil
& Gas facilitiesChallenges
& constraints:
•Physical
isolation
/ weather
/ seasons•Communication•Reliable condition
monitoring
data•Data analysis
and trending
capability•Maintenance
not optimised•Optimising
production
and overall recovery•Maximising
production
availability•Monitoring
and KPI’s
for continual
improvement•Up-turn
/ down-turn
in business•Shortage
of
experienced
competent
staff•Age profile
of
staff•HSE•Corporate
image•Profit
4
Oil
& Gas; Operation
& Maintenance As is (industry
heritage, where
we
are
coming
from
)
5
Valuation
of
potential
for ”Operation
and Maintenance”
through
IO
32% is Operations(15%) and Maintenance(17%), i.e. NOK
96 billion
(US$
15 billion)
6
Integrated Operations / E-field / Smart-field -
a convenient high-profile 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 …….
7
Center
for Integrated Operations in the Petroleum Industry www.ntnu.no/iocenter
NTNUSINTEF
IFE
Oil Companies Suppliers
Conducts research, innovation and education within the IO field, to promote accelerated production, increased oil recovery, reduced operating costs and enhanced safety 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
8
Data processing
Sensor technologyand automation
Visualization
Geographically dispersed teams
Wearable computing
Smarter decisions
RESEARCH CHALLENGES FOR INTEGRATED OPERATIONS
9
Failure detection methods on static “Oil & Gas”
equipment offshore
Detection Method % contribution to detection of failure
Casual observation/ unknown 60-65 %
Periodic preventive maintenance 10-15%
Continuous condition monitoring 10-15%
Inspection 5%
Other (production interference, on demand, functional testing etc.)
5-10%
10
Oil
& Gas facilities: Operation
& MaintenanceChallenges
& constraints:
•Physical
isolation
/ weather
/ seasons•Communication•Reliable condition
monitoring
data•Data analysis
and trending
capability•Maintenance
not optimised•Optimising
production
and overall recovery•Maximising
production
availability•Monitoring
and KPI’s
for continual
improvement•Up-turn
/ down-turn
in business•Shortage
of
experienced
competent
staff•Age profile
of
staff•HSE•Corporate
image•Profit
Vendor: rotating
machines
Subsurface
team: reservoir
Production
/ Maint
team
11
Summary –
Oil & Gas
Data sharing & and remote decision support
will lead to
Increased safety & integrity, reduced emissions
Increased life time of the equipment
Increased process regularity
Decreased operation & maintenance costs
Better, smarter, faster decisions
Monitoring of critical parameters 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 not specified in Philosophies / Tenders as required by company
Man
and Organisation
aspects are at least as challenging as Technology
The costs
due to periodic shutdown and/or decreased efficiency should
be emphasised and highlighted
12
Oil
& Gas; Operation
& Maintenance To be (successful)Alarm
Alert
OK
Safety/integrity
Availability
Technical
Condition
Index
Integrated
Operations:• High
profile
enabler
(O&M; 1/4 of
the
limelight!)
• Shared
situational
awareness
• Decision
support
• Better, faster decisions
and optimisations
• Hence; -
Improved
production, recovery, integrity
and HSE!
13
Outline: other industries c.f. shipping; -
a pre-project proposal
Oil & Gas industry challenges and constraints
Integrated Operations / E-Field / Smart-Field
Center
for Integrated Operations in the Petroleum Industry
Summary; Oil & Gas
Shipping industry challenges and constraints
Management, monitoring & improvement principles
Examples from other industries
Shipping; Collaboration & Remote support -
TOCC
Summary; Shipping
Holistic Coordinated Optimisation for Shipping;
Research Pre-project proposal
After the Research Pre-project
14
Shipping: Operation
& MaintenanceChallenges
& constraints:
•Physical
isolation
/ weather
/ seasons
•Communication
•Reliable condition
monitoring
data
•Data analysis
and trending
capability
•Maintenance
not optimised
•Optimise
operational
efficiency
/ fuel
consumption
•Maximise
time at sea
/ Minimise
off-hire
•Monitoring
and KPI’s
for continuous
improvement
•Up-turn
/ down-turn
in business
•Shortage
of
experienced
competent
staff
•Age profile
of
staff
•Health, Safety
& Environmental
impact
•Corporate
image
•Profit
15
Additional challenge; priorities of stakeholdersRoles:
Ship-owner
Ship-operator
Ship-manager
Charterer
Cargo Owner
(Ship-broker)Contracts:
Voyage Charter
Time charter
Bareboat charter
Demise charter
Affreightment
16
Collaboration
& remote
support The
principles
discussed
here
have been
known
for 20 years
The
following
key
aspects
have recently
changed, making application
of
the
collaboration
principles
more realistic
now:
high capacity wireless communication near the coast and ports(gives new possibilities c.f. high cost satellite systems)
wireless onboard LAN(permit use of handheld equipment supporting communication)
Further developments planned wrt
satellite coverage
The potential advantages for shore based support and optimisation services must be evaluated
17
Outline: other industries c.f. shipping; -
a pre-project proposal
Oil & Gas industry challenges and constraints
Integrated Operations / E-Field / Smart-Field
Center
for Integrated Operations in the Petroleum Industry
Summary; Oil & Gas
Shipping industry challenges and constraints
Management, monitoring & improvement principles
Examples from other industries
Shipping; Collaboration & Remote support -
TOCC
Summary; Shipping
Holistic Coordinated Optimisation for Shipping;
Research Pre-project proposal
After the Research Pre-project
18
Management, monitoring & improvementPrinciple:
That
which
you
don’t
measure,You
can’t
control.
That
which
you
don’t
control,You
can’t
improve.
Parameters (and required
frequency
for monitoring):Targets for the
year
Targets for the
month
Targets for a series of
voyagesTargets for one
voyage
19
planact
check do(monitor)
(correct)
Management, monitoring & improvement
20
Management, monitoring & improvement
Most people
can
now
recognise
that
management
systems are
a cyclic
process, or loop:
ISO 9000
ISO 14001
If
any
of
the
elements in the
cycle
are
missing, the
loop is incomplete, the
system doesn’t
work!
Measurement, analysis
and improvement
21
Management, monitoring & improvementMost people
can
now
recognise
that
management
systems are
a cyclic
process, or loop:If
any
of
the
elements in the
cycle
are
missing, the
loop is incomplete, the
system doesn’t
work!
Norwegian
Petroleum Directorate
Maint. Mgt.
PDO Contract
Management
22
Management, monitoring & improvement
The
table
is now
simplified
to key-words
only, and colour
coded.
23
Outline: other industries c.f. shipping; -
a pre-project proposal
Oil & Gas industry challenges and constraints
Integrated Operations / E-Field / Smart-Field
Center
for Integrated Operations in the Petroleum Industry
Summary; Oil & Gas
Shipping industry challenges and constraints
Management, monitoring & improvement principles
Examples from other industries
Shipping; Collaboration & Remote support -
TOCC
Summary; Shipping
Holistic Coordinated Optimisation for Shipping;
Research Pre-project proposal
After the Research Pre-project
24
Examples from other industries
The required technology and some of the possible functionalities are already available and proven.
The
following
industries
have developed
and successfully
applied these
principles:
Hydro-electric
power
Oil
and Gas
Military/Defence
& Aviation
Space
Medical
care, e.g
”Norsk senter for telemedisin”
Power
generation
& distribution
Railways
others
25
Examples from other industries
Hydro-electric
power
Collaboration
and Operation
Centres
Offshore
Integrated
Operations
Remote
operation
Operation
support centres
Military
Network-based
warfare
Effect-based
warfare
Space
Control Centre
Integrated
logistic
support
JSTARS NETCENTRIC WARFARE (Courtesy
116th ACW)
26
Outline: other industries c.f. shipping; -
a pre-project proposal
Oil & Gas industry challenges and constraints
Integrated Operations / E-Field / Smart-Field
Center
for Integrated Operations in the Petroleum Industry
Summary; Oil & Gas
Shipping industry challenges and constraints
Management, monitoring & improvement principles
Examples from other industries
Shipping; Collaboration & Remote support -
TOCC
Summary; Shipping
Holistic Coordinated Optimisation for Shipping;
Research Pre-project proposal
After the Research Pre-project
27
Improve competence and tools for utilisation of
technical operational data in the maritime industry
An example
of “collaboration”
in shipping
28
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
Other?
29
TOCC project
OFFICE
SHIP
Feedback
Registration
Main engine performance
Auxiliary engine performance
Hull and propeller performance
Infrastructure
Support
User meetings
Management
30
Indexing fleet performance
Alarm
Alert
OK
Ship
Supe
rinte
nden
tFl
eet M
gr. Technical performance
31
TOCC procedure
•Develop forms•Input ship static data•Send forms to ship
•Install forms•Input measure data•Form validate data•Data sent to TOCC
•Receive xml/email•Validate data•Store data•Analyze data•Generate report•Send report to ship•Send report to office
•Receives report•Maintenance
32
Keys to success
Selection and maintenance of instrumentation
Procedures for performance tests
Quality control of practise versus procedures
Feedback and corrective actions
Follow-up of deviations –
responsibility and support
33
TOCC examples
Improvement at fleet level
Improvement at detail level where corrective action can be recognised
34
35
36
Examples from RAF project
Reporting on environmental data
Faster response on reports to crew
A basis for learning
Better feedback
More information
Compare with others
Direct communication shore -
vessel
Less information via inspector
Easier to share knowledge
37
Shipping: Operation
& MaintenanceChallenges
& constraints:
•Physical
isolation
/ weather
/ seasons
•Communication
•Reliable condition
monitoring
data
•Data analysis
and trending
capability
•Maintenance
not optimised
•Optimise
operational
efficiency
/ fuel
consumption
•Maximise
time at sea
/ Minimise
off-hire
•Monitoring
and KPI’s
for continuous
improvement
•Up-turn
/ down-turn
in business
•Shortage
of
experienced
competent
staff
•Age profile
of
staff
•Health, Safety
& Environmental
impact
•Corporate
image
•Profit
38
Summary –
Shipping
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, KPI’s
Data sharing &
and remote decision support
could lead to
Increased safety & integrity, reduced emissions
Increased life time of the equipment
Increased process regularity (Maximise
time at sea
/ Minimise
off-hire)
Decreased operation & maintenance costs
Better, smarter, faster decisions
Monitoring of critical parameters 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 not specified in Philosophies / Tenders as required by company
Man
and Organisation
aspects are at least as challenging as Technology
The costs
due to periodic shutdown and/or decreased efficiency should
be emphasised and highlighted
39
Outline: other industries c.f. shipping; -
a pre-project proposal
Oil & Gas industry challenges and constraints
Integrated Operations / E-Field / Smart-Field
Center
for Integrated Operations in the Petroleum Industry
Summary; Oil & Gas
Shipping industry challenges and constraints
Management, monitoring & improvement principles
Examples from other industries
Shipping; Collaboration & Remote support -
TOCC
Summary; Shipping
Holistic Coordinated Optimisation for Shipping;
Research Pre-project proposal
After the Research Pre-project
40
Holistic Coordinated Optimisation for Shipping; Research Pre-project proposal:
Together
with
stakeholders & interest
groups, identify:
Candidate
parameters / drivers for evaluation
HSE
Emissions and thermodynamic performance of equipment
Mechanical performance of equipment (monitoring & support)
Performance Indicators for key parameters (KPI’s)
Logistics, routing, port arrival & departure
Competence Development & Competence Assurance
and possibly other parameters such as trim, hull condition etc.
Feasibility
Requirements
for key
decisions, frequency
of
info required
Costs, and potential
value
creation
for each
41
Holistic Coordinated Optimisation for Shipping; After the Research Pre-project:
Entirely
dependent on
outcome
of
pre-project; could
be
Further
development
of
necessary
enablers?
Industry
pilot project?
Strategic
research
project?
CRI (Centre
for Research-based
Innovation)?
Critical
questions
for success:
How
good
do we
want
to be?
Where
is the
potential
for improvement?
Can
we
estimate
its
value?
How
good
can
we
be?