sing ship maintenance rev3- 20090511

8/8/2019 sing Ship Maintenance Rev3- 20090511

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1MARINTEK

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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2MARINTEK

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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4MARINTEK

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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5MARINTEK

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




Optimising production and overall recovery

Maximising production availability

Monitoring and KPIs for continual improvement

Up-turn in businessShortage of experienced competent 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




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


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

sing ship maintenance rev3- 20090511

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