Peter Stock, Executive Director, Sentratech, Seattle, Washington, USA

Transcription

1 Peter Stock, Executive Director, Sentratech, Seattle, Washington, USA

2 THE ALASKA EXPERIENCE RELIABILITY CENTRED MAINTENANCE AND ONLINE MONITORING USING THE PI SYSTEM November 2010, Johannesburg

3 ABOUT ALYESKA PIPELINE 800 miles long 48 diameter pipe 5 Pump Stations Marine Terminal 1.4 Million bpd operating capacity Logistics & Operations centers in Valdez, Anchorage, and Fairbanks November 2010, Johannesburg

4 Brooks Range

5 Tanana River Bridge Crossing

6 Valdez Terminal

7 22-24 November 2010, Johannesburg Operation Control Center

8 Background Currently running 42 turbines within 6 pump stations Pipeline throughput drops from million bbpd to 1.1 million bbpd High cost of transporting Alaskan crude Advances in engineering design 2001 Alyeska embarked on a Strategic Reconfiguration (SR) project

9 Strategic Reconfiguration (SR) Primarily involved electrifying and automating the pump stations Power source at each pump station was changed to generated power or commercial power Project included upgrading all control systems using PLCs across the pipeline SR project reduced the number of turbines to 10 and the number of active pump stations to 4

10 Right-of-Way Agreement (ROW) Pipeline crosses Federal and State land Agreement stipulates that all physical assets used on the ROW must a have a maintenance program in place before the assets are put into service Sentratech invited by Alyeska to develop the maintenance strategies for all the reconfigure assets using Reliability Centered Maintenance

11 RCM What is it? Reliability-Centered Maintenanceis a process used to determine what must be done to ensure that any physical asset continues to do what its users expect in its present operating context. ~Moubray, RCM II (1992) Describe functions, failure modes, causes, effects and consequences Measure Performance, Actuarial Analysis, Failure Data Determine appropriate preventative & predictive tasks for each physical asset

12 Evolution of Maintenance Strategies Effectiveness Predictive Model-Based Learning Systems Reactive Break-Fix Run-to-failure Preventative Calendar-based Runtime-based Efficiency

13 Maintenance Strategy Initiatives Mission Ensure pipeline reliability and integrity using advanced maintenance strategies Goals Proactive vs. reactive maintenance Optimize available resources Discover new & better ways to operate Challenges Difficult operating environment Complexities of modernization Attrition of SME s Pressure to reduce operating costs Increasing scrutiny and regulation November 2010, Johannesburg

14 Systems Analyzed Safety integrity pressure protection system (SIPPS) Booster pump building Manifold building Fuel systems Crude pressure relief systems Siemens turbo generators Commercial power supply 2.25 MW standby generators Control module Mainline pump set Remote gate valves (RGVs)

15 Remote Gate Valves (RGVs) March 7 10, 2009 San Diego, CA, USA

16 Maintenance Strategies in Action SCADA Network Maintenance Network Smart Signal Equipment Warnings Predictive SCADA Discrete Maintenance Operational Instrument Alarms Data Reactive PI High Resolution Instrument Data ACE/AF Calculated Events Condition-Based Monitoring AF/ACE Calculated Alarms Condition-Based Monitoring WORK MANAGEMENT Automated PM Completion Corrective Work Orders All All Asset Backlog Preventative EQUIPMENT DIAGNOSTICS AND RESOURCE CENTER (EDRC) Work Order Scheduling

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18 RESULTS The EDRC has demonstrated tremendous value: Centralized access to equipment and system diagnostics Automating 200+ Calendar/Runtime-based PMs Facilitating new Condition-Based Monitoring (CBM) algorithms Providing post mortem and root cause analysis on equipment failures Communicating initial equipment diagnostics with Operations Engineering, OCC, Field Maintenance, and other SMEs Assisting field maintenance with troubleshooting and validating corrective actions taken in the field Reducing intrusive maintenance impacts Preventing unintended shutdowns and equipment outages

19 TANGIBLE BENEFITS EDRC BENEFIT ANNUAL SAVINGS Regulatory Calendar-based PM Automation DOT Valve Strokes Reduced Field Man-Hours $400,000 Function Testing of Valves Reduced Field Man-Hours $100,000 DOT Relief Valve Testing $50,000 Tank Level PM s $35,000 Continuous CBM and PBM Algorithms Unplanned Downtime Avoidance $350,000 Device Deviation Monitoring Reduced Field Man Hrs $150,000 FIRST YEAR ANNUAL SAVINGS $1,085,000

20 Questions?? Peter Stock P.O. Box Bainbridge Island, Washington USA peter.stock@sentratech.com November 2010, Johannesburg