Transcript No Slide Title

Geir Simensen
Honeywell Hi-Spec Solutions
Norway
Strategic Opportunity
The history of seeking profitability from plant
performance has been heavily weighted
toward process operations.
Plant and equipment
availability
Process
operations
Equipment and plant
availability
performance has
been the wild card
in business
performance.
Hi-Spec’s Unified Manufacturing Solutions
Our Purpose
To Help You
Proactively
Manage Your
Assets At The
Optimum Cost
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
A typical Production Profile
for an Asset Intensive
Facility for a calendar year.
95 days
79 days
62 days
47 days
23 days
Days per Year
30 days
16 days
8 days
5 days
< 60%
Daily Production
95%
Production Target set by Enterprise
100%
Rate
620
6 20
6 10
6 00
5 90
5 80
5 70
5 60
5 50
5 40
5 30
5 20
5 10
5 00
4 90
183
180
177
174
172
169
166
163
160
157
154
595
590
584
578
572
567
561
555
549
543
538
532
526
520
3 0 0
610
600
590
580
570
560
550
540
530
520
510
500
490
4 80
151
Total Feed
480
4 70
4 60
148
145
515
509
503
497
492
486
480
474
468
463
457
Frequ en cy
  
470
20
460
Total Fe ed
4 50
4 40
142
F eed
450
440
4 30
4 20
18
16
14
12
10
8
6
4
2
0
430
139
136
200
420
4 10
4 00
133
130
150
410
400
3 90
3 80
3 70
127
124
121
118
115
112
Frequency
2 0 0
390
380
370
15
3 60
3 50
3 40
3 30
3 20
3 10
3 00
2 90
2 80
# Day s
250
360
350
340
330
320
310
300
290
280
# Days
Real Life Examples
His to gr a m
  
1503
2 5 0
$ 2 4.2 M
24.2M
1 5 0
1 0 0
5 0
0
Histogra m
Ra te
10
$33.5 M
5
0
This plant had
$24.2M in lost
capacity due to
asset availability &
incidents!
300
3.2%
5.8%
5.8%
100
50
0
This plant had
5.8% in lost
capacity!
Production rate
$38.5 M
This plant lost
$38.5M!
Ra te
And this plant lost
$33.5M!
Factors Affecting Plant Operations
Between 3-15% in Lost Capacity
is attributed to asset
Plant Operating Target
un-availability and incidents
Planning Constraints
Plant Availability
Operational Constraints
Days per Year
Plant Incidents
Production
Management
NEW EMPHASIS!!
Asset
Management
DCS/APC/ Optimization
efforts
Plant Capacity Limit
< 60%
Daily Production
95%
Manufacturing
Execution
Scheduling & ERP
100%
Factors Affecting Plant Operations
Get that 3-15% in Lost Capacity
Back!!
Planning Constraints
Plant Availability
Operational Constraints
Days per Year
Plant Incidents
Plant Capacity Limit
< 60%
Daily Production
95%
100%
How you manage the health of your assets
IMPROVE
ABNORMAL
SITUATION
ORIENT
You become
“aware” of a
problem.

RESOLUTION
DECIDE
ACT
You determine the
cause and decide
what to do about it.
You take action to
fix or respond to
the problem.
facilitates this work process
IMPROVE
ABNORMAL
SITUATION

ORIENT
You become
“aware” of a
problem.
RESOLUTION
DECIDE
ACT
You determine the
cause and decide
what to do about it.
You take action to
fix or respond to
the problem.
MAINTENANCE
RESPONSE
DIAGNOS DECISION
-TICS
SUPPORT
OPERATOR
RESPONSE
Scouts
•IntelliScout
•TurboScout
•Loop Scout
•Valve Scout
•Transmitter Scout
•and more
Diagnostics
ORIENT DECIDE
ACT
CMMS
DIAGNOS
-TICS
DECISION
SUPPORT
OPERATOR
TOOLS
IntelliScout
Diagnostics
ORIENT DECIDE
•Detects asset
specific
problems before
they occur
–Rotating &
Reciprocating
Machinery
–Heat Exchangers
–Pumps
–Instrumentation
[email protected]
ACT
CMMS
DIAGNOS
-TICS
DECISION
SUPPORT
OPERATOR
TOOLS
Principle of Intelliscout
• Black box statistical model
• Set of correlated variables, relationships
dependent on asset behaviour
Example - Motor Driven Pump
Discharge Pressure,
Specific Gravity
Motor Amps
RPM (if variable)
Flow, Suction Pressure, Temp
Intelliscout
• 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
Algorithms
• 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
Intelliscout
• Trained on data set representing normal
behaviour
• Analytical model may not be possible
– Too complex
– Under instrumented
TurboScout
Performance Monitoring & Optimisation
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
Gas turbines
fault indices
Plant PV
Gas turbines
Compressors
Scrubbers
Coolers
Steady-state
checks
Compressors
fault indices
Fault indices,
alarms and
complimentary
trends
Scrubbers fault
indices
etc.
Coolers fault
indices
Database
of fault
indices
Off-line Model Based Analysis
Optimisation
(fuel consumption)
Database
of fault
indices
from
On-line
system
Model
based
analysis
Predictive
maintenance
Production
based
maintenance
Optimisation
(compressor wash)
• 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 Scout
Transmitter Scout
ORIENT DECIDE
• 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
ACT
Maintenance
DIAGNOS
-TICS
DECISION
SUPPORT
Operators
Valve Scout
ORIENT DECIDE
• 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
ACT
Maintenance
DIAGNOS
-TICS
DECISION
SUPPORT
Operators
What Tools Do You Use for Maintenance?
Oil Analysis
Infrared Thermography
Data Historians
Excel Spreadsheets Open Control Systems
Intelliscout
Loop Scout
Turbo Scout
Manual Calculations
MathCad
Vibration Monitoring
Process Simulation
Calendar
Motor Current Analysis
Computerized Maintenance Management System
Ultrasonic Noise Detection
Integrated Decision Support
ORIENT DECIDE
ACT
Maintenance
DIAGNOS
-TICS
DECISION
SUPPORT
Operators
• 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.
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
Fault files
x
Required evaluation
Evaluation done, nothing
found
Symptom found to exist
 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.
x
Required 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
• Available via our Partners
• Fully integrated with Decision Support
• Work orders triggered automatically
ORIENT DECIDE
DIAGNOS
-TICS
ACT
CMMS
DECISION
SUPPORT
OPERATOR
TOOLS
Benefit - Higher Availability
EXAMPLE:
Fuel consumption
increased
Higher Availability Through:
Compressor moves
toward surge
due to lack of flow
• Early Awareness,
• Effective Troubleshooting,
• Efficient Resolution
Compressor could
not maintain flow
Gas too hot,
Volume larger
Excess turbine
creep life
consumed
Cooler
Fouled
Compressor starts
to recycle gas
Flash Gas Compressor, throughput $290K day
Scenario…
• No symptoms detected
• Display of controllers,
valves and transmitters
indicate normal
IMPROVE
ABNORMAL
SITUATION
ORIENT
You become
“aware” of a
problem.

RESOLUTION
DECIDE
ACT
You determine the
cause and decide
what to do about it.
You take action to
fix or respond to
the problem.
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