knowledge based asset integrity for wind farms
DESCRIPTION
Asset integrity services such as KBAI™ (Knowledge Based Asset Integrity) provide risk profiling for key components based on assessment of data from a variety of sources. This allows owners and operators to better predict where problems will occur. Similar approaches are already regularly used by owners and operators in other industries such as oil and gas. Such systems provide a maintenance and/or inspection task plan that is optimised specifically for the asset and the business. - See more at: http://blog.lr.org/2013/05/kbai-the-definitive-addition-to-your-om-strategy/#sthash.TWKPtbTK.dpufTRANSCRIPT
Lloyd’s Register Energy
Working togetherfor a safer world
Knowledge Based Asset Integrity (KBAI) for wind farms
Andrew MartinTechnical ManagerLloyd’s Register Energy
Lloyd’s Register Energy
Lloyd’s Register Energy
Knowledge Based Asset Integrity (KBAI)
Likelihood of failure(events per year)
•Equipment type and items used•Age, usage, environment, etc•Equipment condition (based on visual inspection, past maintenance, failure causes and condition monitoring, etc)
Consequence of failure (impact per event)
•Disruption to business•Environmental + health and safety impacts•Reputation – public/political
Consequence ranking
ABCDE
HIGH
MED HIGH
MEDIUM
LOW
1
2
3
4
5
Pro
bab
ility
Ra
nkin
g Maintenance and inspection task plan optimised to the asset and the business (£ impact per event)
•Includes industry best practices•May increase or decrease current maintenance
Lloyd’s Register Energy
Lloyd’s Register Energy
Why this approach?
• Improves reliability
• Consequential loss reduction - increasing exported electrical power
• Provides justification for:
• Establishing the correct level of maintenance and hence maintenance expenditure
• Actions to reduce breakdowns such as prioritising replacements
• Integrity measurements for additional failure modes to give further confidence in asset condition
Lloyd’s Register Energy
Lloyd’s Register Energy
Case study – port cranes
• Breakdown duration reduced
• Quay Side crane (QS) ‐24%;
• Rubber Tyred Gantry cranes (RTG) ‐12%
• Maintenance cost savings: QS 17%; RTG 32%
• Significant commercial operational benefits:
• Crane efficiency enhanced
• Containers handled and related safety all improved
• Ship turnaround and throughput improved
Lloyd’s Register Energy
Lloyd’s Register Energy
Case study – oil refinery piping
• Pilot study on fixed equipment on eight process units led to $1.5m in turnaround cost savings and $7m in risk reduction
• Rolled out to 6 further refineries resulting in over $160m in risk reduction and on-going savings in turnaround plans. Achieved within 3 years.
• Key lesson learned is the need to continually audit and manage the system to ensure the alignment of people processes and technology
RBMI - RELIABILITY BASED MECHANICAL INTEGRITYAchieving Value
Identifying the DELIVEREDRISK REDUCTION VALUE
Finding this CUI problem was estimated to save the refiner $2MM.
An additional $4MM in lost production was avoided when RBMI
identified exchanger problems before they could affect the safe operation of
the refinery. This added up to over $6.373 MM in reduced risk all within 3
months of completing the project.
The small branch connection on the line was found to be corroded nearly through-wall. Continued operation without finding and repairing the damaged connection would have resulted in a failure with potentially serious effect.
Lloyd’s Register Energy
Lloyd’s Register Energy
What-if Analysis
Cumulative Risk Curves Safety Losses
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
1,800,000
1 60 119 178 237 296 355 414 473 532 591 650 709 768 827 886 945 1004 1063 1122 1181 1240 1299 1358
Equipment Component Count
Cu
mu
lati
ve
Ris
k (
$ /
yr) As-Found Risk
Risk Distribution
20 1 10 5 5 0 0246 2 72 81 74 18 1235 3 71 77 74 12 1238 4 76 71 71 17 3232 5 88 35 36 65 8
E D C B A971 317 269 260 112 13
Risk Distribution
2 1 1 1 0 0 0238 2 61 81 79 17 0248 3 91 70 74 13 0251 4 76 82 71 17 5232 5 88 35 36 65 8
E D C B A971 317 269 260 112 13
As-Left Risk
90% Risk Reduction Achieved by
Addressing 10% of Equipment
Cum
ula
tive R
isk (
$ /
yr)
Lloyd’s Register Energy
Lloyd’s Register Energy
Configuration: Risk units & probability factors are identified for each asset type
Risk Units
Probability Factors
Lloyd’s Register Energy
Lloyd’s Register Energy
Generate planned maintenance tasks
System Type A
Lloyd’s Register Energy
Lloyd’s Register Energy
The prediction for next year shows criticality has changed for five risk units – undertake pre-emptive work on these
Date for criticality calculation
Criticality change
Lloyd’s Register Energy
Lloyd’s Register Energy
Summary
• Capture relevant data to make informed decisions and update risk profile both at implementation stage and through life
• Update maintenance planning and task priorities
• Provide effective failure mode management in response to changing equipment condition
• Record operating knowledge even if staff/contractors change
• Facilitate knowledge transfer across the asset portfolio
Lloyd’s Register Energy
Lloyd’s Register and variants of it are trading names of Lloyd’s Register Group Limited, its subsidiaries and affiliates.Copyright © Lloyd’s Register Energy. 2014. A member of the Lloyd’s Register group.
Andrew MartinTechnical Manager, RBMI AberdeenLloyd’s Register EnergyE: [email protected]
Lloyd’s Register Energy71 Fenchurch Street, London EC3M 4BS
Working togetherfor a safer world
Follow LR Energy on LinkedIn
@LREnergy