Integrity Management of UGS

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1 Integrity Management of UGS Vniigaz-Gazprom UGS 2011 conference Moscow Winfried Becker, VNG Verbundnetz Gas, AG Leipzig(D) Michael Kaiser, PC-Soft GmbH, Senftenberg (D)

2 Topics Company overview Integrity Management by Basic overview Solutions for gas storage by Best practice in UGS Management Case-study VNG- Verbundnetz Gas AG aims, decisions, results, next steps Conclusion Modules and benefits of Bild 2

3 UGS facilities of VNG - Verbundnetz Gas AG Bild 3

4 UGS Facilities of VNG - Verbundnetz Gas AG Bild 4

5 Company Profil I PC-Soft GmbH Software solutions for technical asset management, condition monitoring and maintenance Headquarter in Berlin - Area Office Rhine-Ruhr Düsseldorf More than 1500 user licenses installed worldwide Business Unit Railway Business Unit Industry Business Unit System Integration Transport Minerals l Metals l Mining Oil l Gas l Chemistry Production l Environment IT Infrastructure Bild 5

6 Bild 6 Best practice by PC-Soft

7 Topics Company overview Integrity Management by Basic overview Solutions for gas storage by Best practice in UGS Management Case-study VNG- Verbundnetz Gas AG aims, decisions, results, next steps Conclusion Modules and benefits of Bild 7

8 The global figure Owner Investor Technical data operations data Management knowledge Plant Manager decisions Targets strategic Management Service Management Operation Management Insurance company aims Basis Plant Data (component & ínfrastructure) Strategy, Concepts Projekts, Methods Roules for inspections Bild 8

9 Plant Asset Management of UGS - general overview Bild 9

10 Asset Monitoring as a basis Asset Bentchmark on focus (in accordance to VDI/ VDE 2651) Operation (Opex) Cost Classification Safty-/ Risc-analysis Global Diagnostic Benchmarking Abnormality Condition ASSET Cashflow Efficiency / Profit Benchmark Prognosis and and Renewable Strategy Forecast Task, Jobs Classification Availability Dashboard, Cockpit, Info Info Portal Reports Bild 10

11 Continuously improvements Process data & service information Condition information Plant/process knowledge Management decisions Plant Process Condition Monitoring, Tele-diagnosis Maintenance Management Asset/Plant Management (Remote) monitoring and analysis of process data and plant condition, initiation of predefined rule- (condition/load) based tasks Planning, controlling and optimisation of preventive, corrective and condition based maintenance processes Optimisation of industrial assets, plant operations, maintenance resources and strategies as well as asset valuation during the complete life cycle Alarms (notice guidance) Maintenance requests plant and process analyses by engineering staff Process data archiving Bild 11

12 Integrity Management of UGS Define Indicators (KPI) Evaluate current situation Define improvement strategies Monitor improvements index of technical plant safty index of plant reliability technical safty Bild 12 reliability

13 General procedure to work on improvement potentials Step 1: Determining relevant plants and components Bild 13

14 General procedure to work on improvement potentials Step 3: Analysis of experiences and create asset status parameter Character 1 age of the asset/ plant 2 condition of the asset in % of the capacity in normal mode 3 type of load 4 pressure ratio 5 operation monitoring 6 presence of gas substances 7 safety release valve 8 present operating experience Attribute < 10 years, 11 to 15 years, 16 to 20 years or > 20 years > 30 % resp. < 70 %, 10 to 30 % resp. 70 to 90 % and < 10 % resp. > 90 % Static, tumescent or impulsive > 0,5 (sub critical) oder <= 0,5 (over critical) teleservice, tele signalised, locally registered or locally indicating No accompanying substances, hard or liquid substances with or without filters With or without membrane break security device no, rare or often deviation from the targeted condition Points und oder 20 0 bis 40 max. 160 points for y-axis of the risk matrix Bild 15

15 General procedure to work on improvement potentials Step 4: decision about maintenance and plant optimisation Preparatory analysis Data collection and evaluation Technical, organisational cycle Risk matrix Selection of maintenance strategy Optimisation of maintenance strategy Conclusion and evaluation Bild 16

16 How to find the best MRO strategy? Risk of fault Detection Index high preventive preventive condition based RCM Strategy low corrective Condition based low high consequence of unplaned down-time Severity Index (Cost Index) Bild 17

17 MRO Strategy in accordance to DIN MRO Strategy Korrektive Vorbeugende Zustandsabh ä corrective Instandhaltung (Ausfallstrategie) preventive Instandhaltung (Pr äventivstrategie) condition Instandhaltung based Improvement Maintenance Instandhaltung Diagnostic Diagnose Plant Asset Management Anlagenmanagement Bild 18

18 Topics Company overview Integrity Management by Basic overview Solutions for gas storage by Best practice in UGS Management Case-study VNG- Verbundnetz Gas AG aims, decisions, results Conclusion Modules and benefits of Bild 19

19 UGS management UGS management by IWCM injection and wihtdrawal capacity management Compliance/ reporting IWCM storage management energy consumption maintenance/ services storage capacity Bild 20

20 IWCM - UGS management at VNG DMS Document Management- System (GDMCOM ) SAP PM (VNG) Asset Management IWCM Storage Service Asset History, Asset Availability Workforce Management Storage Operation Injection and Withdrawal Capacity Management (IWCM) Cavern Balance Calculation Energie Load Prognosis Storage Trading (VNG) Energie Trading (VNG) 3D-Geo-Simulation (UGS Mittenwalde) SCADA (DCS and EEAS by ELPRO) System Portex (RWE- ESK) Bild 21

21 storage capacity and energy information ERP (SAP PM) External Data (Cavern, Aquifer) Workforce Management (manual data input) OPEX IWCM cockpit Storage Trading Service Manager Cavern Capacity Calculation SCADA (PLC+CMS) Operations Manager Energy Manager Bild 22

22 Topics Company overview Integrity Management by Basic overview Solutions for gas storage by Best practice in UGS Management Case-study VNG- Verbundnetz Gas AG aims, decisions, results Conclusion Modules and benefits of Bild 23

23 Bild 24 UGS Bernburg

check and report of safety equipment Highlights Recording of all switch operations during the standard operation of the plant Plausibility check of switch operations Generation of switch operation

24 check and report of safety equipment Highlights Recording of all switch operations during the standard operation of the plant Plausibility check of switch operations Generation of switch operation reports for safety evaluation procedures User Benefits Savings in time for legal security switches tests and reports for authority Improving of safety by uncovering of incorrect purposes of security switches Bild 25

mobile inspection and maintenance support User Benefits Processing of inspections, checklists, maintenance and overhaul orders Access to master data, meter readings and maintenance and overhaul

25 mobile inspection and maintenance support User Benefits Processing of inspections, checklists, maintenance and overhaul orders Access to master data, meter readings and maintenance and overhaul history On-site acquisition of defect and failure data, measurement values and meter readings Highlights Increases quality and productivity of maintenance and overhaul processes Enables direct on-site access to condition data, maintenance and overhaul history Facilitates data acquisition on failures, measurement values and meter readings Permits immediate documentation of all maintenance and overhaul measures Optimises processing times for maintenance and overhaul procedures Achieves excellent user acceptance thanks to it's easy and fast touch functionaliy Bild 26

26 Bild 27 business information & reports

Diagnostic and Analysis Highlights Online processing of operating data and load based maintenance management Technical diagnosis of plants and components based on long-time process data Condition

27 Diagnostic and Analysis Highlights Online processing of operating data and load based maintenance management Technical diagnosis of plants and components based on long-time process data Condition monitoring of equipments, plants and process lines Support of plants and mines benchmarking User Benefits Optimization of mining operation processes and plants Identification of bottlenecks and cost drivers in wind machinery Optimization of maintenance strategies and workforce management Benchmarking of plants and suppliers Bild 28

28 Bild 29 Analysis and Reports

29 Bild 30 R&D project: Ejector

30 Bild 31 Ejector in operation

31 Bild 32 Cockpit UGS Bernburg (VNG)

32 Bild 33 zedas asset cockpit working gas capacity

Managing faults doing improvments Fault detection by SCADA Fault detection by people Fault detection by operaions Load detection Classing tool Time based decicions message

33 Managing faults doing improvments Fault detection by SCADA Fault detection by people Fault detection by operaions Load detection Classing tool Time based decicions message workorders request Dispatching Service Management Benchmarking A1 B1 C1 A2 B2 C2 A3 B3 C3 A4 B4 C4 A5 B5 C5 Reporting Work order management D1 D2 D3 D4 D5 E1 E2 E3 E4 E5 Bild 34

34 zedas asset key features Increase of availability Guarantee and increase required plant availability by optimising scheduled and reduce unscheduled downtimes consolidating, documenting and using plant-related experience and knowledge in order to support decisions optimising plant performance Minimise risks Monitor and evaluate plant condition Support targeted choice/ application of maintenance strategies trace activities to change stock of assets/ plants and operating modes Bild 35

35 zedas asset key features Minimise cost Increase in efficiency of all activities in terms of sustaining and enhancing assets Guarantee production efficiency by optimising deployment of external services Monitor cost development Increase in operating efficiency by minimising breakdowns/ downtimes Optimise energy consumption Bild 36 Collection and analysis of obtained process data in the field of energy consumption Optimise mode of operation of plants and aggregates

36 zedas asset key features Compliance with rules Comply with all technical rules and standards (particularly DVGW G 495) Verify usage of safety and operating instructions Comply with technological requirements and operating parameters as well as obtain/ preserve various certificates Storage capacity and quality calculation Gas delivery from diffenrent explorations Gas quality parameter different Ensure constant quality to gas transportation Reports to authorities Bild 37

37 Topics Company overview Integrity Management by Basic overview Solutions for gas storage by Best practice in UGS Management Case-study VNG- Verbundnetz Gas AG aims, decisions, results, next steps Conclusion Modules and benefits of Bild 38

38 zedas asset - modules and add-on Add-ons Bild 39

Workforce management Highlights Co-ordination of human resources as well as

Visualization as spreadsheets, diagrams or matrices Management of technical

for workshops and service teams depending on there needs Detecting and avoidance of

39 Workforce management Highlights Co-ordination of human resources as well as utilities and tools Resources utilization transparency of linked processes Visualization as spreadsheets, diagrams or matrices Management of technical qualifications and authorizations User Benefits High quality workforce management for workshops and service teams depending on there needs Detecting and avoidance of bottlenecks in service staff, materials and equipment Optimization of the service resources utilization Bild 40

40 Focus on availability Stock Manager Bild 41

41 Focus on key figures - LCC/KPI/Prognose - CalculatoR Bild 42

42 Bild 43 Focus on KPI zedas asset cockpit

43 Asset Management Reports & Statistik Standard-Reports Web-Reports Adhoc-Reports Dashboards Business Intelligence Analysis Office-Integration Bild 44 SAP 2008 / Page 44

44 Multiple use of information Type of users Owner Operator... Insurance Investor Web Portal External Worker Service-Teams Datendase Server Different plants PCS-Connect PCS-Connect PCS-Connect PCS-Connect Datenbank XML PCS-Connect PCS-Connect Firma^/Anl. F Datenbank XML... Plant A Server Plant. B Plant G Server Bild 45

45 Any question? Our Bild 47

46 Thank you very much! Don t hesitate to contact us in case of any additional question! Kontakt PC-Soft GmbH Adolf-Hennecke-Str Senftenberg Germany fon +49(35 73) fax +49(35 73) sales@pcsoft.de web Bild 48

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