Egil Birkemoe, ABB Integrated Operations September 24, 2009 Slide 1
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
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
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
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
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
References, Business Cases and Concepts StatoilHydro: Oseberg East, 2003-2005 Brage, 2003-2005 Oseberg C; 2003-2004 Troll B and Troll C; 2004-2005 Centre for Heavy Rotating Machinery at Sandsli; 2006 Oseberg South, 2006-2007 Oseberg Field Centre; 2006-2007 Troll A, 2006 Gullfaks A, B, C; 2006-2007 Part of TAIL R&D program (including Gassco); 2006-2009 IO Compliance 2008-2009 Petoro Gullfaks A, B, C; 2005-2006 KPI reporting; 2006 The Norwegian Oil Industry Association Integrated Operation Potential at Norwegian Continental Shelf; 2006 BP Shell Valhall Re-development; 2004-2010 Draugen; 2005-2006 Ormen Lange; 2003-2007 Teekay, Frøy 2008-2009 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
September 24, 2009 Slide 8
cpmplus Topology Oil & Gas September 24, 2009 Slide 9
Production Optimization September 24, 2009 Slide 10
Active Flowline Control: Field result Pipeline Inlet pressure Pipeline inlet pressure Oil production from Tor [-] Oil production from Wellhead Platform 14 15 16 17 18 19 20 days Slugging, resulting in a loss of oil production Slugging eliminated, oil production increased by ~10% September 24, 2009 Slide 11
Sand Erosion Monitoring: Field Result Insight allowed Statoil to add production on the Gullfaks field 2003-300 mill USD 2004-190 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
TT flare 3403 TIC 3402 E-301A TT 3421 TIC flare 3420 E-301B PT PT 40380 3040 WP PIC 8043 PI PT 8066 8043 Hod PV--8043A TI PI 1072 1073 TI PI PV--8043B 1074 1075 DP A DP B PIT PIT PIT TIT TIC PIC 120020 120053 38703 38718 38853 38881 North Flank PV--38881 PIT PIT 110020 110053 X-305 PV--38877 0E-316 South Flank PIC PIT TIT TI PI 38877 38753 38768 1076 1149 DP Test 25.01.2006 -P-303A -P-303C -P-303B P PIC 3452 LC 3415 LV--3415 LC 3433 LV--3433 FIC P 3543 FV--3543 P FIC 3594 FV--3594 SIZE FSCM NO DWG NO REV A3 1 SCALE 1 : 1 SHEET 1 OF 2 FT 3501 FT 3551 P PT FIC 3521 3501 FV--3501 P PT FIC 3573 3551 FV--3551 PT 3011 LIC 3043 PT 3105 LIC 3134 S S PI 3155 PIC flare 3030 PV--3030 -V-301 Separator PIC flare 3116 PV--3116 -V-302 Separator PIC flare 3171 PV--3171 -V-303 Separator (test) LV--3101A LV--3101B LV--3007A LV--3007B excess fuel gas from 340-001 TIC TTflare 3601 3602 LC E-302A 3608 LV--3608 TT TIC 3621 flare 3621 LC E-302B 3627 LV--3627 TT 3033 TT 3120 FQI 3166 P LC 3616 LV--3616 LC 3635 LV--3635 LIC 3021 LV--3021 LIC 3115 LV--3115 LIC 3170 PIC 3652 LV--3170 FIQ 3161 FIC 3786 P FT 3675 FT 3751 P FT 6358 P FIC 3698 FIC 3751 PT 3695 FV--3751 P FIC 3654 FV--3654 PT 3695 PT 31620 0E-310A 0E-310B TIC 3222 TIC 3230 gas from stabilizer feed tank (329-01) FIC P 31423 PIC 31420 P PT FT TT 31420 3675 TIC 3802 flare 3801 FV--31423 LC 3814 LC E-306A 3806 LV--3814 FIC P 31623 LV--3806 TT 3820 TIC flare 3819 FV--31623 LC 3832 FT LC E-306B 3777 3824 LV--3832 P LV--3824 PT 3305 PT LT 6355 6354 -V-332 PW Flash Tank flare PIC 3266 LIC 3251 LIC 3301 PT 3255 FI 6387 -P-372A -P-372B PV--3316 PV--3266 -V-304A Crude Flash Drum PIC 3316 LSLL 3258 LV--3251 LSLL 3308 -V-304B Crude Flash Drum LV--3301 LIC 6368 T-375 LCV--6369 LIC 3265 LIC 3315 -P-373A FIC 3675 -P-302A -P-302C -P-302B FT 6366 FV--3675 S to filters PT 3692 PT 3794 FIC 3777 FV--3777 FIC 3355 FIC 3350 S FT 36100 PT 3888 3 rd stage suction cooler (318-001) FV--3350 FT LV--3265 3350 LV--3315 FT 3355 flare FV--3355 flare flare flare M PT LT 80940 80836 XV--80839 PT LT 80950 80846 XV--80849 PT LT 80960 80856 XV--80859 PT LT 80970 80866 XV--80869 PT TT 4705 4701 LIC 80888 LIC 80883 LT-80836 LT-80856 flare TIT AT 80897 80895 P export to Ekofisk 2/4 J XV--80873 LV--80871 LV--80883 PI 80893 -PA-8120A LIC PI PT 84199 -PA-8120B 80894 80887 LIC FT 80871 80896 to seawater WP production header PT 80886 Process Monitoring -K-301B -K-301C PT 3554 -K-302A.1 -K-302C.1 -K-302A.2 -K-302C.2 HGF HLF PDIT 38855 -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
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
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 9 8 7 6 [Sm3/d] 5 4 3 September 24, 2009 Slide 15 2 1 0
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
Example display, electromechanical September 24, 2009 Slide 17
Performance Monitoring, Compressor Expected performance Actual performance September 24, 2009 Slide 18
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
Shell - Ormen Lange Covers 20% of UK gas request 12bn USD project Production startup 2007 September 24, 2009 Slide 20
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
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, > 50 000 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
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
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
Users Shell Nyhavna Draugen Shell Råket Shell WAN Shell Risavika ABB Service Environment September 24, 2009 Slide 25
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 26 130 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.
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 e-mail 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
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
BP Valhall re-development project In operation: 2010 Greenfield Brownfield September 24, 2009 Slide 29
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
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
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
Wireless Vibration Sensor http://www.otcnet.org/2008/spotlight/ September 24, 2009 Slide 33
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 3.41 3.15 11. 42 10. Y- 0.12 60 10. CVM Y-GP 0.30 15 9.2 X- 0.72 0 10. CVM X-GP 0.75 16 13. 9 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
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
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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
CPM = Collaborative Production Management Business Transactions based typical Database Applications GUI: HTML-based, slow Norm ISA-95 specifies Structures, Models, Functionalities! (see http://www.isa.org/ ) 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 http://www.abb.com/cpm 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
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
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
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
Instrumentation Example September 24, 2009 Slide 42
LV SWBD and MCC Monitoring (MNS is) September 24, 2009 Slide 43