Egil Birkemoe, ABB Integrated Operations. ABB Group September 24, 2009 Slide 1

Transcription

1 Egil Birkemoe, ABB Integrated Operations September 24, 2009 Slide 1

2 Simulator Feasibility Study Concept Selection FEED EPC Production start Operation Modifications Steady state calculations Engineering Simulator DCS test Operator Training Simulator Operation Support Lifecycle simulator HYSYS OLGA INDISS (RSI) OLGA September 24, 2009 Slide 2

3 Mature and Tail end Challenges Caracteristics of TAIL phase Process equipment not optimized Aging equipment More maintenance intensive Run as long as profitable Integrated Operations - main contributor to increase life of field Production Increase Production Minimize OPEX Start-up Plateau Mature Tail Abandonment September 24, 2009 Slide 3

4 Value of Integrated Operations on the Norwegian Shelf Based upon 58% of all Norwegian oil and gas production and extrapolated 6 % 29 % Accelerated Production Improved availability Reduced O&M cost Reserve increase Reduced drilling and w ell cost 43 % 12 % 10 % September 24, 2009 Slide 4

5 Planned maintenance: Maintenance cost distribution for 10 north-sea fields: Distribution 1 Safety equipment 11,7 % 2 Electric power distribution 11,3 % 3 Instrumentation 10,6 % 4 Piping specialities 8,7 % 5 Lifting 8,1 % 6 Pressure vessels and storage tanks 5,7 % 7 Piping, pipeline, risers and umbilical 5,0 % 8 AC, equipment for refrigeration 5,0 % 9 Turbines 4,4 % 10 Manually operated valves 4,2 % 11 Pumps 3,8 % 12 Power generation/transformation 3,8 % 13 Communication equipment 3,1 % 14 Other 3,1 % 15 Safety relief valves 3,0 % 16 Combustion engines 2,6 % 17 Actuator operated valves 0,9 % 18 Not relevant 5,2 % 100,0 % September 24, 2009 Slide 5

6 Smart Field system design Broad-band Connection Onshore Operation Center Company Expert Resource Center Advanced Control and Optimization tools September 24, 2009 Slide 6 Supplier Support Center

7 References, Business Cases and Concepts StatoilHydro: Oseberg East, Brage, Oseberg C; Troll B and Troll C; Centre for Heavy Rotating Machinery at Sandsli; 2006 Oseberg South, Oseberg Field Centre; Troll A, 2006 Gullfaks A, B, C; Part of TAIL R&D program (including Gassco); IO Compliance Petoro Gullfaks A, B, C; KPI reporting; 2006 The Norwegian Oil Industry Association Integrated Operation Potential at Norwegian Continental Shelf; 2006 BP Shell Valhall Re-development; Draugen; Ormen Lange; Teekay, Frøy ConocoPhillips 2/4L, 2007 Greater Ekofisk Area Development, 2009 R&D with StatoilHydro, BP, ConocoPhillips, ENI E-operation Wireless Vibration sensor TAIL Wireless Sensor Network September 24, 2009 Slide 7

8 September 24, 2009 Slide 8

9 cpmplus Topology Oil & Gas September 24, 2009 Slide 9

10 Production Optimization September 24, 2009 Slide 10

11 Active Flowline Control: Field result Pipeline Inlet pressure Pipeline inlet pressure Oil production from Tor [-] Oil production from Wellhead Platform days Slugging, resulting in a loss of oil production Slugging eliminated, oil production increased by ~10% September 24, 2009 Slide 11

12 Sand Erosion Monitoring: Field Result Insight allowed Statoil to add production on the Gullfaks field mill USD mill. USD Statoil reported in SPE 94511: During 2004 a total of 95 mill. USD (1,9 mill. bbl) of additional revenue was achieved on the Statfjord field... September 24, 2009 Slide 12

13 TT flare 3403 TIC 3402 E-301A TT 3421 TIC flare 3420 E-301B PT PT WP PIC 8043 PI PT Hod PV--8043A TI PI TI PI PV--8043B DP A DP B PIT PIT PIT TIT TIC PIC North Flank PV PIT PIT X-305 PV E-316 South Flank PIC PIT TIT TI PI DP Test P-303A -P-303C -P-303B P PIC 3452 LC 3415 LV LC 3433 LV FIC P 3543 FV P FIC 3594 FV SIZE FSCM NO DWG NO REV A3 1 SCALE 1 : 1 SHEET 1 OF 2 FT 3501 FT 3551 P PT FIC FV P PT FIC FV PT 3011 LIC 3043 PT 3105 LIC 3134 S S PI 3155 PIC flare 3030 PV V-301 Separator PIC flare 3116 PV V-302 Separator PIC flare 3171 PV V-303 Separator (test) LV--3101A LV--3101B LV--3007A LV--3007B excess fuel gas from TIC TTflare LC E-302A 3608 LV TT TIC 3621 flare 3621 LC E-302B 3627 LV TT 3033 TT 3120 FQI 3166 P LC 3616 LV LC 3635 LV LIC 3021 LV LIC 3115 LV LIC 3170 PIC 3652 LV FIQ 3161 FIC 3786 P FT 3675 FT 3751 P FT 6358 P FIC 3698 FIC 3751 PT 3695 FV P FIC 3654 FV PT 3695 PT E-310A 0E-310B TIC 3222 TIC 3230 gas from stabilizer feed tank (329-01) FIC P PIC P PT FT TT TIC 3802 flare 3801 FV LC 3814 LC E-306A 3806 LV FIC P LV TT 3820 TIC flare 3819 FV LC 3832 FT LC E-306B LV P LV PT 3305 PT LT V-332 PW Flash Tank flare PIC 3266 LIC 3251 LIC 3301 PT 3255 FI P-372A -P-372B PV PV V-304A Crude Flash Drum PIC 3316 LSLL 3258 LV LSLL V-304B Crude Flash Drum LV LIC 6368 T-375 LCV LIC 3265 LIC P-373A FIC P-302A -P-302C -P-302B FT 6366 FV S to filters PT 3692 PT 3794 FIC 3777 FV FIC 3355 FIC 3350 S FT PT rd stage suction cooler ( ) FV FT LV LV FT 3355 flare FV flare flare flare M PT LT XV PT LT XV PT LT XV PT LT XV PT TT LIC LIC LT LT flare TIT AT P export to Ekofisk 2/4 J XV LV LV PI PA-8120A LIC PI PT PA-8120B LIC FT to seawater WP production header PT Process Monitoring -K-301B -K-301C PT K-302A.1 -K-302C.1 -K-302A.2 -K-302C.2 HGF HLF PDIT VD-8010A -VD-8020 Recycle from filters -VD-8010B Overall Process Diagram -VD-8010C Created by Espen Storkaas/ Espen Reinertsen -VD-8010D September 24, 2009 Slide 13

14 Rotating Equipment Condition/Performance Monitoring KPI/Portal/Performance PIN Historian (Electrical) (Vibration) (Process) PC N DCS Note: Time Synchronization View Signals OPC/Modbus/etc. September 24, 2009 Slide 14

15 Rotating Machinery, Example By condition and performance monitoring, turbine maintenace stops can be reduced Vibration analysis Turbine performance analysis Unplanned: Trip of critical equipment Planned: Turbine maintenance Planned [Sm3/d] September 24, 2009 Slide

16 Electro systems Medium and High Voltage switchboard Transformers, oil filled Generators Power from shore Motors Drive systems Transformers, dry September 24, 2009 Slide 16 Low Voltage switchboard, motor startes

17 Example display, electromechanical September 24, 2009 Slide 17

18 Performance Monitoring, Compressor Expected performance Actual performance September 24, 2009 Slide 18

19 Automation Asset Management Servers, Clients, Software, Network, Firewalls Drive systems Controllers and I/O MCC and SWBD Instrumentation icl. valves September 24, 2009 Slide 19

20 Shell - Ormen Lange Covers 20% of UK gas request 12bn USD project Production startup 2007 September 24, 2009 Slide 20

21 Experience; Involment in all phases Success is best ensured with close cooperation through all phases Process followed at Ormen Lange, Valhall re-development and others Influence concepts Select the right content and infrastructure Instrumentation Infrastructure Framework Applications Support Tuning Calibration Set-up Support Tuning Optimization Concept FEED Basic/Detail Design Commission Start-up Operation September 24, 2009 Slide 21

22 ABB a differentiator ABB Norway: Extensive competence and experience to maximize benefits from integrated operations. Organized under Integrated Operations department approx. 65 employees More than 100 projects, > hrs, control room operations High competence, > 10% with PhD A leading service provider Proven tools and work processes (ABB Service Environment ) Norway and international September 24, 2009 Slide 22

23 Customer Case: Shell Service Level Agreement Value: Duration: Sites: 95 MNOK Excl. site and mod. work 5 year agreement + options Draugen and Ormen Lange ABB is Single Point of Contact for all Automation related issues Independent of vendor Independent of the case type (Incident/ Event etc) ABB is Single Point of Contact for Change and Configuration Management Updated Site Inventory independent of vendor ABB perform & assist in System Operations to match Shell s Information Security Policy. Remote work/collaboration facility at ABB premises Remote system monitoring integrated with Site Inventory ABB responsible for System evolution planning September 24, 2009 Slide 23

24 ARMOR (ABB Remote Monitoring & Operations Room) Work which is performed here: Service Maintenance Operation Support Tuning and Optimization Modification projects Benefits: Immediate response Easy access to ABB specialists Less travel reduces cost and ensures more work Production loss can be significantly reduced September 24, 2009 Slide 24

25 Users Shell Nyhavna Draugen Shell Råket Shell WAN Shell Risavika ABB Service Environment September 24, 2009 Slide 25

26 Service Desk & status of teams Single Point of Contact Informed Service Desk Shared tools, including third party = up to date All inquires using common Work Process Model Efficient use of internal and external competence clusters Level 1 team Service Desk Agents Level 2 team Simulator Level 2 team EOP APC og Tuning support Level 2 team EOP Asset Optimizer Level 2 team EOP PIMS / IMS support Level 2 team Safeguard Level 2 team Advant OCS Level 2 team 800xA September 24, 2009 Slide specialists from different ABB locations contribute in 30 different Level 2 Teams Level 3/4 teams are supporting Level 2 teams. Specialist competence from ABB factories, R&D Level 2 team Insum Level 2 team Elektro Level 2 team Telekom Level 2 team 3 party etc.

27 Secure Client Server Management (SCSM) Remote System Alarm Handling SOIL ABB Firewall in SOIL ABB ARMOR Dedicated Network Customer s Corporate Firewall to SOIL ABB Service Desk Environment 2Mb Dedicated Line Customer s Corporate Office Network ABB Server Environment Protected Zone Network Firewall Duty Watch Plant s Terminal Server ServiceDesk Plant s DMZ Alarm Incident Change Configuration CMDB Asset Optimizer 800xA System Work Order/ Permit/ SJA? Plants PCDA / Safety /Elctro Trusted Zones CS2 OK CS2 (Failed) When An work alarm has is sent been to completed, the alarm console CMDB database in Service desk, Configuration When The Based System Alarm CS2 is fails, information specialist sent Management through alarm starts about is to generated Database working the incident to (CMDB) and solve relevant is used is updated and The After If System alarm incident through ABB Connectivity sms approved with is specialist necessary processed involves sent Work to the Service the SMS desk and environment, Server access any Order records. through duty changes and watch CS2 the Service plant Work Messaging is to cellphone. the from Permit, desk system ARMOR the job to the Information get issue, information and utilizes CMDB, of the ARMOR Work system, Order, facilities restore Work to service procedures Permit monitor and or Based tool, can hardware to a in where 800xA monitored be do specialist executed. a the diagnosis or content software, is is system. processed. by assigned Asset the a change system. alarm, to Optimizer the process the service duty desk is watch started. case. other and possible troubleshoot relevant Safe information. Job the Analysis system. are. prepared. can determine the criticality of the incident. September 24, 2009 Slide 27

28 Integrated Operations - Service Environment ABB takes responsibility for the services, operations and modifications required to operate the automation systems on modern oil, gas and petrochemical facilities Single Point of Contact Shared tools, including third party All inquires using common Work Process Model Efficient use of internal and external competence clusters, fast access through remote access Includes advanced solutions & services (production & asset mgmt.) Remote access to facilities through secure infrastructure Reduced travelling = improved HSE September 24, 2009 Slide 28 Work processes and supporting tools according to automation practices and ISO standards

29 BP Valhall re-development project In operation: 2010 Greenfield Brownfield September 24, 2009 Slide 29

30 R&D, Technology areas F1 Condition and Performance monitoring F2 Turnarounds and shutdowns Integrated Operations! Concepts for safe and cost-effective operations of facilities F6 Robotics technology F5 Mobile ICT infrastructure F3 Wireless communication F4 Collaborative visualization September 24, 2009 Slide 30

31 Integrated Operations - Wireless NOW Long-haul data transfer Long-haul wireless Remote Plant Localization (Personnel and assets) Mobile Operator (Access to real-time plant data and devices for configuration, calibration etc.) Monitoring (wireless sensors) Plant Network Server Network Aspect Server Operator Workstation Engineering & Monitoring Workstation Device/IED Device/IED Personnel / Asset Tracking Mobile Worker Plant Network Mobile Operator Station Open-Loop control for non-critical assets (Wireless Devices & Fieldbus) Control Network OPC Connect Connectivity Server Device/IED Device/IED Device/IED Device/IED Mobile Worker Closed-Loop control Wireless Safety FUTURE Field Network AC 800M Device/IED Device/IED Device/IED Device/IED Device/IED Device/IED AC 800M Device/IED Device/IED Device/IED Device/IED Device/IED Device/IED September 24, 2009 Slide 31

32 WiVib Wireless Vibration Sensor Vibration monitoring of LV AC motors Size below 400kW Non-intrusive (very simple installation) Fully autonomous Small, inexpensive, wireless Long battery life Suitable for EX environment WirelessHART ratified in Sept 2007 No commercial product in the market today using WirelessHART (april 2008) ABB cooperates with DUST among others Developing an innovative system consisting of lowcost high quality sensor units that communicate their measurements wirelessly to a central unit. Currently, condition monitoring is too costly because of installation, wiring etc. System enables the monitoring of the condition of existing equipment in an cost efficient way September 24, 2009 Slide 32

33 Wireless Vibration Sensor September 24, 2009 Slide 33

34 ENI R&D Cooperation - Campobasso test Geophone data (GP) & CVM (ABB) data Even t149 Velo c. mm/ s Fre q. Hz Z- CVM Z-GP Y CVM Y-GP X CVM X-GP Test using:din 4150 trigger level 3 Ref. Vibrato r 80%/10 Hz 80%/10 Hz 80%/10 Hz 80%/10 Hz 80%/10 Hz 80%/10 Hz September 24, 2009 Slide 34

35 Overview of Wireless Vibration sensor (WiVib) Consortium headed by ABB Status (June 2008): Prototype tested Financing in place for product phase Sponsor: Initial solution September 24, 2009 Slide 35 Prototype

36 September 24, 2009 Slide 36

37 cpmplus SmartClient Create your own graphics on your plant interests some examples: Auto-Access to all 800xA Online & Trend Data Access to all Alarm & Events, incl. Event Statistics Easy to configure, needs just a few minutes to learn! September 24, 2009 Slide 37

38 CPM = Collaborative Production Management Business Transactions based typical Database Applications GUI: HTML-based, slow Norm ISA-95 specifies Structures, Models, Functionalities! (see ) Business Systems (ERP, CRM, CMMS,, also proprietary Solutions) Level 4 Timeframe: months, weeks, days, shifts Production Quality Inventory Maintenance Production Process Transactions Challenge: Needs to speak to both sides: Business & Automation Systems! GUI: needs to be able to show content from both sides! ABB has already a wide scope of Industry specific solutions from different CoE s around the world! Pulp & Paper Solutions Chemicals Solutions Minerals Solutions Cement Solutions Oil & Gas Solutions Level 3 Timeframe: day, shift, hour, minutes, seconds Operate & Closed-Loop Control Real-time & communication / OPC GUI: Real-time with strong Operator focus Continuous Batch Discrete Automation Systems Sensors, actuators and logical devices, control & operate Level 0, 1, 2 Timeframe: Realtime, seconds September 24, 2009 Slide 38

39 cpmplus Knowledge Manager (KM) SmartClient Panels: Enterprise-wide, web-based Information Portal Excel Access Graphics & Trends Advanced Reports Alarms Analysis $ LIMS *1) $$ 800xA Firewall cpmplus Knowledge Manager Report Engine Other RDBMS Data Alarm & Events Aggregates Fast Raw Data Storage Calculation Engine Firewall.NET/WS ODBC OPC..it s the next generation Information Manager for 800xA! 800xA Firewal l DC cpmplus Data Collector pure TCP/IP based! DC DC auto-reconnect! buffered send! 800xA Auto Log Config Seamless Trends *1) = available as extra Solution based on cpmplus Core Product September 24, 2009 Slide 39

40 DriveMonitor TM Intelligent monitoring and control Functions Monitoring of drive s performance, and, if required, other shaft line components (main circuit breaker, transformer, motor) Continuous monitoring of status and respond when changes occur. Predefined diagnostic actions, prosessing and reporting. Early detection of potential failure Fast fault finding process Easier root cause analysis reduced Mean Time To Repair (MTTR) September 24, 2009 Slide 40

41 HV and MV Switchgear monitoring Monitoring Single-line Diagram and busbar coloring Time stamped event and alarm list Parameter settings Disturbance record upload sampling rate of 1.2 khz a maximum of 5 seconds September 24, 2009 Slide 41

42 Instrumentation Example September 24, 2009 Slide 42

43 LV SWBD and MCC Monitoring (MNS is) September 24, 2009 Slide 43