value of partnerships and collaboration for...0.15 0.2 0.25 0.3 0.35 0.4 0.45 0 0.5 0 0.5 0 0.5 0...
TRANSCRIPT
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© Copyright 2010, OSIsoft LLC. All rights reserved.
Value of Partnerships and Collaboration for
World Class Performance Monitoring
Brianne LaBry, IT Project Manager
Chevron Global Power
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Agenda
• Chevron Global Power (CGP) & Power Support Center (PSC)
• PSC Performance Monitoring Tools
• PSC Enterprise Value Creation (EVC)
• Value Realization Practices (VRP) Initiatives
• Value of Enterprise Agreement (EA) and Collaboration
• Q&A
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4
Chevron Global Power
• Vision - To be the Chevron Center of Excellence for power…recognized
for our commercial, technical, operational and regulatory expertise.
• Mission - We develop, generate and sell power and associated services
as an integral part of Chevron’s value chain, with power operations
acknowledged as world-class in operational excellence.
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5
Cogeneration
March Point, WA
Black Mountain, NV
Garnet Valley, NV
Cogeneration
Mid-Set, CACogeneration
Sycamore, CACogeneration
Kern River, CA
Cogeneration
Coalinga, CACogeneration
Salinas River, CA
Sunrise Power, CA
Cogeneration
Sargent Canyon, CA GS Power (Anyang)
South Korea
GS Power (Bucheon)
South Korea
Tri Energy Company
Thailand
Amata EGCO Power
Thailand
Amata Power Ltd
Thailand
Chevron Global Power Facilities
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6
Chevron Enterprise Facilities
Power Facility
Office Location
Leveraging Organizational Capabilities
Richmond Best Practice
Assessment
Global Refining
SJVBU Best Practice
Assessment
NAE&P
Power Support Center Pilot (El
Segundo)
Global Refining
Organizational
Capability Project
SA/PNZ SBU
Pembroke Cogen
Global Refining
Agura IPP
CNL Best Practices
Implementation
IBU
SRC Cogen
Singapore Refining Co.
Tengiz Best Practice
Implementation
TCO
Power Market Assessment
Tool ERCOT Purchasers
CHP & GHG Advocacy
Regulatory Support
PSN & PSC
Technical Support
Piceance Transmission Line
Interconnect
NAE&P
CVX Power Portfolio Expansion
Casper Wind
Power Project
EMC
Cedar Bayou Cogen Plant
CP Chem
Gas Monetization
San Pascual Power Project
ASBU
O Mon Power Complex
ASBU
Bibiyana Power Project
ASBU
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Business Case
• Ownership and/or operational interest
in a diverse fleet of power generating
assets around the world
• Success of our business depends on
keeping our operations running reliably
and efficiently
• Can experience significant reliability
and efficiency Lost Profit Opportunities
(LPO’s)
• Can leverage existing power expertise
and help maintain institutional knowledge
91
92
93
94
95
96
97
98
99
100
Availability Reliability
Industry CGP Chevron
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Monitoring & Diagnostics Center
Power Solutions Network
Business planning support
Operations philosophy and tools
Maintenance philosophy and tools
Engineering and technical solutions
Performance monitoring/trip analysis
Training/OC development
Equipment modifications and upgrades
Power Support Center
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Power Support Center Organization
Major Inspection
Management
PerformanceMonitoring & Diagnostics
TurbineParts
QA/QCMetallurgist
Expertise
PIAdministration
EngineeringAnalysis
ProjectManagement
O&M Philosophy &
Tools: OE Compatible
Equipment Assessment &
Upgrades
Oil & Gas Operations
Refineries
BusinessPlan
Development
KPITracking
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© Copyright 2010, OSIsoft LLC. All rights reserved.
Performance Monitoring Tools
OSIsoft Enterprise Agreement for data infrastructure:
• PI ProcessBook
• PI DataLink
• PI ACE
• PI MDB
• PI WebParts via SharePoint
• AF2.0 (future)
• Notifications (future)
• Network Operating Center (NOC)
• Center of Excellence (CoE) and Enterprise Project Manager (EPM)
SmartSignal for predictive analytics:
• SmartSignal EPI*Center
• SmartSignal Watchlist
• SmartSignal participates in the weekly PSC/ES teleconference.
• Initially hosted and monitored by APC, recently transitioned to CVX
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What is SmartSignal ?
11
Machine Trip
Time DifferenceEarly Warning
Upper Threshold
Lower Threshold
Dynamic
Band
Ambient Temp
Oil Supply Temp
MW
Oil Drain Temp.
Bearing Vibration
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Network Architecture
12
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PSC Work Flow Process
APC
PSC Ops Engineer
Weekly Calls
Summary Reports
SmartTrackingPortal & Log
EmailDirect Calls
PSC Ops Engineer
OSIsoftEA
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14
PSC Pilot Project
Avoidance of two cogen unit trips eliminating LPOs of $200,000
Full avoidance could range to excess of $4 MM
Potential avoidance of four additional cogen unit trips with similar LPO avoidance of $100,000 to $2 MM per event
Performance Monitoring - PI $600,000 - $4 MM
Equipment efficiency: Analyzed and designed plan increasing cogen capacity, thus reducing power purchases by over $1.7 MM annually
Capital Stewardship Efficiency: Supporting analysis for the elimination of $5.2 MM in capital project expenditures
Efficiency $6.9 MM/Year
Critical combustion component parts tracking initiative, insuring cost effective unit reliability and avoidance of catastrophic unit failure
Estimated critical combustions parts purchase savings of over $1.2 MM over the next 6 year maintenance cycle
Critical Turbine Component Life Management $200,000/Year
Minimum Savings Maximum Savings
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PSC Site Deployments
15
• El Segundo Refinery
• TECO
2008
• TCO
• Casper
2009
• Richmond Refinery Pilot
2010
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SmartSignal Implementations
• El Segundo
• 3 GE Frame 6s + HRSGs
• 1 Steam Turbine
• 1 Auxiliary Boiler
• 2 Sets of BFWPs
• TECO
• 2 GE Frame 9 + HRSGs
• 1 Steam Turbine
• TengizChevroil
• 1 GE Frame 5
• 2 GE Frame 9 + HRSGs
• 7 GE Frame 6 (future)
• Richmond (future)
• 2 Alstom GT8s + HRSGs
• 1 Steam Turbine
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© Copyright 2010, OSIsoft LLC. All rights reserved.
Enterprise Value Creation (EVC)
• Catches
• Trips
• Efficiency / Capacity Improvements
• Tool Development / Process Improvement
• Organization Capability
• Critical Component Lifecycle Management (Parts)
• Lost Profit Opportunities (LPO)
• Engineering Analysis
• PSC Man Hours
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Catch - HRSG High Conductivity
• HRSG water conductivity trended out of tolerance
• HRSG reliability jeopardized
18
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Catch - Generator Seal Leak
• Noticed correlation in steady increase in generator fan DP and
decrease in hydrogen purity
• Oil found in sensing element
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Catch - Heat Exchanger Fan Failure
• Fan on the cooling water heat exchanger failed causing higher than normal bearing temperatures
• Prevented extensive heat damage and equipment failure
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Catch - Generator Stator Temperature
• Sensor flat lined
• Instrument placed on work list and repaired
21
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Trip – Erratic Vibrations
BTRN BB1 VIBRATION
BTRN BB2 VIBRATION
BTRN BB4 VIBRATION
BTRN BB5 VIBRATION
BTRN BB7 VIBRATION
BTRN BB8 VIBRATION
BTRN BB9 VIBRATION
BTRN BB12 VIBRATION
ATRN MEGAWATTS
\\es-pi\34VI2421
IN/S
\\es-pi\34VI2422
IN/S
\\es-pi\34VI2423
IN/S
\\es-pi\34VI2424
IN/S
\\es-pi\34VI2426
IN/S
\\es-pi\34VI2427
IN/S
\\es-pi\34VI2428
IN/S
\\es-pi\34VI242X
IN/S
\\es-pi\33JI100
MW
A Train Seismic Vibrations
12/13/2007 8:52:47.96155 AM 1/3/2008 8:52:47.96155 AM21.00 days
5.E-02
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0
0.5
0
0.5
0
0.5
0
0.5
0
0.5
0
0.5
0
0.5
0
0.5
0
45
42.203
4.9635E-02
4.9635E-02
0.23859
0.21942
0.20576
0.21168
0.16104
0.16559
• Gas turbine vibration probes were erratic and caused forced outages
• Trip indications not observed, no mitigating actions taken
• PSC detected failing seismic probe and recommended repair
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Efficiency Improvements
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Parts – Turbine Repair
Refurbished Blade Ring
• 300 MW power for oil production field producing 200,000 bbls heavy
crude oil using steam injection
• PSC located blade ring in Houston repair shop, managed repair and
delivery to site
• Prevented a potential loss of approximately $18 million in power and
steam production
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Network Operating Center (NOC)
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Network Operating Center (NOC)
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PSC Enterprise Value Creation (EVC)
• 10,000+ Engineering Hours delivered to PSC sites
• Over 55 Process & Instrument Catches
• 5-6 Trips Avoided
• ~$35-$40MM in EVC to Chevron
27
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PSC Enterprise Value Creation (EVC)
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PSC Enterprise Value Creation (EVC)
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CoE VRP Initiatives
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PI ProcessBook Displays
31
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PI ProcessBook Displays
32
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PI ProcessBook Displays
33
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PI ProcessBook Displays
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PI ProcessBook Displays
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PI ProcessBook Displays
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PI ProcessBook Displays
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PI ProcessBook Displays
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PI ProcessBook Displays
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PI Module Database (MDB)
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PI Module Database (MDB)
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PI Module Database (MDB)
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PI MDB Displays
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PI MDB Displays
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PI MDB Displays
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PI and SmartSignal
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PI and SmartSignal
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PI Advanced Calculation Engine (ACE)
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Benefits of Standardized Visualization
• Standard presentation across sites
• Standard navigation across sites
• Consistency for tag recognition
• Incorporate best graphics and tools from sites
• Re-usable across similar sites
• Color association with trend data
• Less maintenance
• Fewer displays
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Challenges
• Agreeing upon naming convention
• Time/research to initially map tags correctly
• Standardized engineering units
• Optimal viewing in different environments
• Ability to customize when needed
• Version control
• Will always have disagreement
• Capturing Enterprise Value Creation
• People / resource constraints
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Collaboration
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Performance Monitoring
SS alerts
PI data/trends
“Catches”
Notifications to Site
Planned Maintenance
Unplanned Maintenance
Project Management
Site Requests
Technical Documents
Drawings
Quotes
Schedules
Budget
Work Scopes
Outages
Schedules
Scopes
Outage Reports
Meetings
Preparation
Agendas
Action Items
Minutes
Resolution Tracking
Service Agreements
Milestones
EVC Tracking
EVC Agreement
Annual Report
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PSC SharePoint Site
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PSC SharePoint Site
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PSC SharePoint Site
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Task List and Workflow Process
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Value of Enterprise Agreement
• Unlimited PI tags and software licenses, annual training credits
• Established centralized network architecture at PSC
• Assist with PI integration at each unique site
• Provide 24/7 monitoring and notifications of PI system health and performance (NOC)
• Assist with VRP Initiatives
• Provide technical support and evangelism for PSC sites
• Bi-weekly status conference calls
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OSIsoft Tech Support / NOC
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OSIsoft Tech Support / NOC
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Value of Collaboration
• OSIsoft
– Additional knowledge and resources
• SmartSignal
– Enhanced tool set for performance monitoring
• PKO Services
– Experienced integrator developing visualization solutions
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Future Plans
• Continued development of performance monitoring tools
• Continued development of Visualization
• Continued development of SharePoint environment
• Re-evaluate VRP Initiatives
• Evaluate and implement PI software upgrades (AF?)
• Service Agreements with additional sites
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Conclusion
• Knowledge is Power !!
• Visualization helps interpret data
• Data must be accessible and accurate
• Data should be presented in meaningful context
• Standardization for efficient use of tools and data
• Sharing of best practices and tools
• Collaboration is key to PSC success
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Thank you
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