Remote operation Towards unmanned production in remote and harsh climates

Transcription

1 Remote operation Towards unmanned production in remote and harsh climates More efficient More predictable More reliable Safer siemens.com

2 Digitalization for O&G Integrated Digital Solutions Topsides 4.0 Designed for reduced CAPEX and OPEX Shorter project cycle time Shorter time to stable operation with training, virtual commissioning on the digital twin Reduced interfacing risk with integrated automation and safety systems Lower OPEX with reduced manning and predictive analytics Focused on Offshore Production, Topsides 4.0 delivers value to our clients by reducing interfaces, providing integrated operations, reducing TCO, mitigating risk and cycle time reduction through enhanced Digitalization, Rotating Equipment, Electrification and Automation solutions. Automation, safety, control and telecom Motors & Drives for multiple services Power distribution Compression Power generation (gas turbine, generator) Cyber Secure Digital Solutions Thrusters, motors and drives Page 2 September 2018

3 Topsides 4.0 Data persistence and collaboration - from Concept Digital Twin starts Concept & FEED Configurators for fast, best practice designs Integrated EICT, designed for remote operations Detailed design data Digital Twin expands Design & Build Data Backbone P&IDs ICSS Process simulation for concept selection 3D drawings Isometrics Electrical Load Lists Single Line Diagrams Digital fabrication, virtual commissioning Equipment data sheets Life Cycle data Time series data etc. Cyber Secure Cyber Secure Analytics for equipment optimization Analytics for process optimization Service and maintenance data for asset management Real time and historical asset generated data Digital Twin matures Operate & Maintain Page 3 September 2018

4 Topsides 4.0 The Intelligent Digital Twin Digital Twin starts Concept & FEED Configurators for fast, best practice designs Integrated EICT, designed for remote operations Detailed design data Digital Twin expands Design & Build Data Backbone Process simulation for concept selection Plant Twin Smart 3D view for construction planning, field training, etc Process Twin Dynamic process model for automation testing, ops training, what-if scenarios. MindSphere Automated Monitoring Analytics and alerts for process & equipment monitoring OEM Services Predictive diagnostics & asset optimization Digital fabrication, virtual commissioning Cyber Secure Cyber Secure Analytics for equipment optimization Analytics for process optimization Service and maintenance data for asset management Real time and historical asset generated data Digital Twin matures Operate & Maintain Page 4 September 2018

5 Example Savings For A Mid Size FPSO (100k bpd) Reduce cycle time 3 9 months 12 wks saving in preparation of detailed design spec 8 wks shorter engineering phase on rotating equipment 4 wks faster to first oil Reduce CAPEX $ m Optimized design at FEED stage Reduced accommodation for offshore staffing Flexibility and fewer changes with later start of EICT engg Reduced risk from integrated control systems Reduced client engineering and project management Reduce OPEX > $ 100 m over 10 yrs Reduced Shorter Early offshore manning and safer turnaround times warning of performance degradation Page 5 September 2018

6 Remote Control Onshore control Room Ivar Aasen platform 1000 km away from onshore control room Offshore Control Room Twin Aker BP Trondheim Ivar Aasen Onshore Control Room Ivar Aasen Ivar Aasen Maximized production Reduced offshore manning and OPEX Operated in real time from onshore control room Integrated Electrical ICSS-Digital solution Advanced condition based maintenance of critical equipment Process optimization through advanced process control Lifecycle process simulation and training software for training in safe environment Page 6 September 2018

7 Operation scenerio and objectives Remote and harsh environment Harsh weather, sea states, ice bergs, pack ice, poor visibility... Maintenance Apps/ Dashboard Vendor/Experts Low offshore staffing philosophy Multi-skilled crew (subject to local considerations) During normal operation the plant is controlled from the onshore control room Offshore control room used if onshore control room cannot execute control High focus on data analytics transfer all recorded data All functions for stable / safe production available offshore - even if link to shore lost Package suppliers involved early to focus on: low periodic maintenance high degree of condition and performance monitoring readiness for maintaining their equipment remotely specify the requirements enabling them to do so Onshore Offshore IMS Process Assets Control System PCS 7 Page 7 September 2018

8 Automation and Digitalisation Philosophy With low staffing: automated ICSS functions to minimize operator intervention if shore connection is lost or FPSO needs to disconnect Emphasis on integration of equipment with Class 1 ICSS - control functions fully integrated utilising project standard software and control unit hardware Extend condition monitoring use - reduce hours in inspection and test both by crew and class - Smart Class notation Focus on preparing for more use of data analytics - address at an early stage in a project to ensure sufficient data quality Analytics based optimizing of process settings to be automatically transported back to the process domain for activation => Cyber security perspective : Systems and software performing automated optimization located at onshore control room - Edge not Cloud Page 8 September 2018

9 ICSS Set Up Onshore to Offshore Control Page 9 September 2018

10 ICSS Set Up for Onshore to Offshore Control (Network) Page 10 September 2018

11 What about data capacity? Ivar Aasen Data to onshore historian: Event driven communication 1 GB/day = 0,7 MB/min Operator data: 1Mbps Latency below 30 ms Geostationary satellites: 0,5 kbps to 1,4 Mbps / Latency 500 ms VSAT (Inmarsat 5th Gen) today: 6Mbps Low orbit services (soon): 500 Mbps Latency below 50 ms Page 11 September 2018

12 Remote Control Requirements Onshore control Room Ivar Aasen OCR OCR for unmanned installation SAS, Telecom and CAP Evaluate if all components should be redundant and located in separate buildings (fire areas) ICSS and Telecom Two HMI stations and CAP UPS for ½ hour No emergency generator If evacuation - offshore CCR must be manned UPS for ½ hour Emergency generator if low local power stability By evacuation portable HMI to be used WiFi needed Redundant OCR close by but in other building with separate net If both network to offshore fails ESD must be triggered Page 12 September 2018

13 Remote Control Maintenance of Assets Data quality must be - Excellent CCR Operator consoles User dependent Dashboards Individual Signals Analytics Layer Combination of Signals Time stamping close to action PCS 7 controllers HIGHWAY EVENT BASED COMMUNICATION Data Storage Process Data Maintenance Data Meta Data 3rd party systems Page 13 September 2018

14 Remote Control Maintenance of Assets Availability of data for vendors Remote Expert Center User dependent Dashboards Experts Diagnostics Team Analytics Layer Alerts EICT Individual Signals Combination of Signals Data Storage Experts Local Storage Data Lake Process Data Maintenance Data Meta Data 3rd party systems Page 14 September 2018

15 Closing Remarks Control from shore does not need high data capacity, but latency is important Onshore control room is normally in complete control of the plant Less operators offshore, more skilled roles onshore offshore staffing significantly less Use Class 1 controls to ensure highest data quailty available for condition monitoring Transfer all data (including metadata) Enable remote analysis on complex equipment and enable expert investigation Involve key suppliers to ensure necessary features agreed and adopted by all Plan and execute all this from day 1! Page 15 September 2018

16 Contacts: Oslo, Norway St. Johns, Canada siemens.com

17 Back Up

18 Integrated Asset Management and Condition Monitoring Functions Individual Signals User dependent Dashboards Analytics Layer Combination of Signals ELECTRICAL EQUIPMENT UPS Transformers, VSD HV/LV Switchgear, HV/LV Breaker INSTRUMENTS & AUTOMATION Instrument diagnosis (Hart) / Transmitter monitoring ICSS diagnosis, Network monitoring, Computer monitoring Cabinet monitoring, Telecom systems monitoring ROTATING EQUIPMENT Vibration/Temperature Monitoring Performance Monitoring (pumps/compressors) VALVES Valve monitoring (movement/operations) PSV & Control valve monitoring Valve leakages Partial Stroke, Shutdown analysis PROCESS Control Loop Monitoring Heat exchanger Page 18 September 2018

19 Package Integration Access from shore Time sychronisation Control class 1 Control class 2 All controllers available through Engineering Station All controllers get same sychronisation telegram. Alarms time stamped in controller Need separate link / Engg Station. Typically not in base scope. Makes maintenance more difficult and time consuming Must be communicated separately. Time stamp must be included in serial link telegram. If not, time stamp in receiving controller (less accurate) Testing All controllers tested in the same way. In addition to functional testing, interface and translator must be developed / tested HART Interface to instruments Included in infrastructure. All instruments available in same database/application Separate HART network must be added. Separate (parallell) instrument database HMI Common look and feel for all packages May not be standardised, harder to be accustomed Local control panels Not needed, unless required for local commissioning Required, takes space and cabling effort, contains control logic Page 19 September 2018

20 Overview Maintenance: Alarm Statistics Page 20 September 2018

21 Overview Production Page 21 September 2018

22 Overview Process: Trend Window Page 22 September 2018

23 Asset Details: Motor Page 23 September 2018

24 Detailed Trends: Analyzing Examples Page 24 September 2018