ABB Asset Management System - Ifea … · ABB Asset Management System ... ABB and 3rd party PLC...

Tor Ole Bang-Steinsvik, Integrated Operations

ABB Asset Management SystemEICT Equipment Condition MonitoringPerformance Monitoring

72+ M.Eng and 8 Ph.Dwithin:

Process Automation Eng.Computer ScienceMechanical Eng.Electrical Eng.Chemical Eng.Petroleum Eng.Geology

ABB Integrated Operations

Asset Management - Why?Top Level System

Overall ViewCustomized GUI on enterprise level – MS Sharepoint

Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance Monitoring

Today’s topics

ElCT system - FPSO

Base System servers Panel 800 System Workplaces

Extended Operator Workplaces

AC 800MHigh IntegrityController

ABB and 3rd partyPLC & DCS

Fire & GasAlam units

Shut-down

WirelessHART

S900 I/O

S800 I/O

WirelessHARTGateway

LV Switchgear

Variable Speed Drive

MotorController

AC 800MController

Protection &Control IED

Plant Network,ERP, CMMS…

System Networks

Field Networks

SubstationAutomation

ProcessElectrification

ProcessInstrumentation Safety PLC & DCS

System integration

The Challenge – Reduce Operational Expenditures

Distribution1 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 %

Maintenance cost distribution for 10 north-sea fields: 40% EIT

Operational expenditures at the Norwegian shelf, according to DNV studies

Condition MonitoringPhilosophies

Reactive Maintenance -”Fix when error occurs”

Costly with regards toProcess downtimeConsequential lossesOvertime costsSpare part storage

Preventive Maintenance -”According to plan”

ProsAvoids break down

Increased equipment lifetime

ConsUnnessary maintenance can occure

Risk of introducing faults

Predictive Maintenance -”According to actual need”See next slide

Predictive Maintenance”According to actual need”

30-40% more cost efficient than reactive maintenance (*)8-12% more cost efficient than preventive maintenance (*)Increased lifetimeLess need for storageSafer (HSE)

Online condition monitoring makes it possible to predict condition - based on long time logging and deeper analysis

* Source: US Department of Energy (http://www1.eere.energy.gov/femp/program/om_predictive.html)

Conditon Monitoring System

Note:Time Synchronization

Signals

OPC/Modbus/etc.

(Electrical) (Vibration) (Process)

Portal

(Performance Monitoring)

Today’s topics

Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitoringPC, Network and Software MonitoringPerformance MonitoringReferences

Solution Hierarchy and Decision LoopsLe

Local MMI

MaintenanceWorkplace

ProcessInsightPerformance

Monitoring

ERP/EAM

SpecialisedDashboards

SystemViewer

Technology Exams

• Fast Raw Data Storage

Alarm & Events

Aggregates

Other RDBMS Data

800xA Historian

.NET/WSODBC

800xA History Database

Report Engine

800xAFirewall Firewall

800xAFirewall

Excel Access

Calculation Engine

“Advanced Reports”

Graphics & Trends

Alarms Analysis

cpmPlusEnterprise Connectivity

Business Systems

ECS PlugIn

cpmPlus Data Collectorpure TCP/IP based!auto-reconnect!’buffered send’ !Supports 800xA Log

Configuration Aspects

ABB Industrial IT Platform

Top Level System Architecture

Asset Optimizer Maintenance Workplace

800xA History

Process Historian + Model and information (ECS)

Data Warehouse

MS Sharepoint

MS BI Reporting Services

ABB IO Web Applications /

Web Parts

3rd party Web Applications /

Web Parts

Plant Network

Technical Networks

PerformanceOptimization

Userconfigurable

Web GUI

OPC DA/HDAWeb Services

BAPIWeb Services

ISA-95ISO 15926

Asset Management /

Expert Applications

Data Collector in SAS

MS Sharepoint – Compressor Drive Monitor example

Today’s topics

ABB Industrial IT Platform

Top Level System Architecture

Asset Optimizer Maintenance Workplace

800xA History

Process Historian + Model and information (ECS)

Data Warehouse

MS Sharepoint

MS BI Reporting Services

ABB IO Web Applications /

Web Parts

3rd party Web Applications /

Web Parts

Plant Network

Technical Networks

PerformanceOptimization

Userconfigurable

Web GUI

OPC DA/HDAWeb Services

BAPIWeb Services

ISA-95ISO 15926

Asset Management /

Expert Applications

Data Collector inSAS

Continuous Monitoring of all sub-systems in one workplaceAlarm including cause and suggested actionFacilitates drill-down to detailed diagnostic functionsSurveillance and Statistics for maintenance planning

Platform for collaboration between user groups, engineering disciplines and locations

Monitoring

Reporting

Analyzing

Decision

ActionSubmit

Maintenance Workplace

Notify

Maintenance WorkplaceCommon Maintenance view for all Assets

Asset Monitors identify severity of asset performance degradation

What is an Asset Monitor?

Asset specific function block that verifies asset related input dataaccording implemented maintenance and diagnostic rulesUse real-time production and control dataKeep “score” for the asset performanceCorrelation of data in asset contextProvide visibility to “big picture”Transmit the information to those able to act

Other personnelOther systems

Asset MonitorProduction Personnel Data

Automation System Data

MES/ERP Data

SCE DataReal-time Asset Information

Maintenance System Topology

Maintenance Workplace2nd. and 3rd.

Line users

Today’s topics

Electrical system CM

Drive Monitor

Medium Voltage SWG Monitor

Transformer Monitor

HV SWG Monitor

Low Voltage ACB and MCC

Monitor

Sea cable Monitor

Online Vibration Monitor

Wireless Vibration Monitor

HV/MV Switchgear Monitor – Relion Protection Relays

Trip coil

Contact wear

Energizing circuit

Breaker travel time

Breaker inactive time

Spring charging time

Transient disturbance recorder

HV/MV Switchgear Monitor – Relion Protection Relays

Electro Condition Monitoring – IEC61850

Sensycal Temperature Monitoring – MV SWG

Contactless IR temperaturemonitoring of contact points and conductor rails on MV-level

Reporting to MaintenanceWorkplace by Asset Monitor

LV Circuit Breaker Monitor

Local bus unit

Trip coil

Contacts

CB statuscontacts

Temperaturesensor

Trip unit,electronic

Currentsensors

LV Motor Control Centre Monitor - MNS iS

MNS iS

DriveMonitorTM

DriveMonitorTM diagnostic system:Early detection of potential failureAlerts including possible cause and recommendations for corrective actions through Maintenance WorkplaceRemote access allows support from external expertPredefined diagnostic logging functions, processing and reportingMonitoring of drive’s performance, and, if required, other shaft line components (main circuit breaker, transformer, motor)

DriveMonitorTM

TEC – Transformer Monitor

The TEC (Transformer Electronic Control) is a diagnostic system which provides:Statements about the operating condition and load ability predictionDiagnoses and recommendations for corrective actions if problems with the transformer should occur (oil/winding temperature, tap-changer wear, moisture and hydrogen content in oil)Prediction of the consumed lifetime based on overload forecasting and winding hot-spot calculationsOptimum cooling performance according to load and controlled wear on cooling pumps and fans

MV/LV Dry Transformer Monitoring

Monitoring of windingtemperaturesReporting to MaintenanceWorkplace by Asset MonitorWeb-MMI accessiblethrough MaintenenanceWorkplce

Sea cable monitoring

Based on fiber optic distributed temperature sensing (DTS)

Provides continuous and repeatable measurements, in real-time, of the location and the temperature of many thousands of points along the optical fiber sensor.

The environment of a submarine cable, particularly at the ends, can change. Monitoring the temperature will alert the maintenance system should the cable, for example, be stretched or bent, since the stress on the cable will change.

Individual sections of the cable can be identified as different zones (i.e around a buoy) that can be independently programmed to generate an alarm via the maintenance system when the temperature in any zones reaches a pre-set limit, thus helping to both protect the cable and prevent outages.

Graphical user interfaces, temperature profiles and data are integrated into Asset Optimizer.

Today’s topics

Vibration Monitoring- the objective

Proven technology for predictive maintenance of rotating equipment

Detect incipient failure

planand

prepare Shutdown and

repair

Cost effective means of avoiding production loss and minimising

maintenance costManual data gathering today - Ideal opportunity for wireless technology

Protection system- to prevent catastrophic failure

Primary safety system with safety critical performance standards

Shut machine

down within msec

Wired systems are preferable (for now)

Wireless Vibration System – WiMon100

Condition Monitoring of rotating equipment

(OPC)Asset Monitor Integration / OPC

Vibration serverABB Analyst frequency analysis 800xA Asset Optimizer

Maintenance Workplace

Today’s topics

Maintenance WorkplaceElectrical System Condition MonitoringVibration MonitoringField Device MonitioringPC, Network and Software MonitoringPerformance Monitoring

Field Device Monitor

HART based instruments and field devices monitored via the Maintenance Workplace

Transmitters

Gas detectors

Valve positioners

Maintenance Workplace provides easy access to the instrument vendors device specific MMI’s (e.g. HART DTM’s)

Root-cause fault finding

Performance optimization

Co-operation with Solberg Andersen on Valve Monitoring

PST by Metso Positioners

Valvewatch for selected safetyvalves

FieldKey - WirelessHART Adapter

Today’s topics

PC, Network and Software Monitor

All IT assets monitored via the Maintenance Workplace

Servers

Switches

Controllers

Maintenance Workplace provides easy access to the device specific MMI’s

Easy fault finding

Performance

Today’s topics

Asset Management – two main work processes

• Examples include:• Mecanical faults with

equipment• Sensor failures• Electrical faults• Detectors

Emergingequipment fault

• Fault detected by monitor

• Alert plant operators ofemerging fault(Alarm/Event)

• Initiate investigation

Alert and investigate • Inspect equipment

• Perform diagnosticsusing available tools

• Consult with Subjectmatter experts

Diagnose

• Generate work orders• Perform maintenance

Decide and implement

• Examples include:• Reduced efficiency of pump

and compressor strings• Fouling in heat exchangers• Reduced separator efficiency• etc

Performancedegradation

• Automatic identification ofdegraded performance

• Assessment of criticalty• Suggested actions• Notification to relevant personell

Identify • Detailed evaluation of rootcause

• Detailed assessment ofcriticality

• Update identificationmodelsand suggestes actions

Diagnose

• Update maintenance plan• Issue work orders

Decide and implement

Field Equipment ManagementMainly targeting maintenance

as part of daily operationShort decision cyclesTightly linked to or integrated in control system

Process Equipment ManagementDiagnostics supporting long-

term maintenance planning and managementLonger decision cyclesLinked to corporate maintenance management systems

Knowledge transfer

Features:Standard performance tool library (DIN, ASME) Generic models (Pumps, Compressor, Heat

Exchangers, etc.)

Online thermodynamic modelsContinuous comparison between actual and expected plant performance. => Calculates performance deviationsTie-back to Maintenance Workplacefor maintenance planning

Benefits:Reduces fuel costsImproves predictive maintenanceEarly detection of degradationsAccepted calculation norms Typical payback <2 years

ProcessInsight Performance Monitoring

Performance deviations

Shell Ormen LangeOrmen Lange Service EnvironmentTM Agreement

ABB is Single Point of Contact for all Automation System ServiceIndependent of vendorIndependent of the case type (Incident/ Event etc)Change and Configuration ManagementUpdated Site Inventory independent of vendor

ABB perform & assist in System Operations Remote work/collaboration facility at ABB premises

Process Tuning SupportRemote system condition monitoring

Automation System MonitoringTelecom System MonitoringInstrument MonitoringHeat Exchanger Monitoring

ABB responsible for System evolution planning

BP Valhall - Asset Management provided by ABB

Automation / InstrumentationHART Field Device MonitoringTransmitter Discrepancy MonitoringAnalyzer MonitoringSafety/Shutdown systems

Automatic Shutdown ReportValve Verification and Partial Stroke Testing

ICSS and Telecom Monitoring (servers, networks, I/O controllers, software processes)

ElectricalElectrical switchgears, LV and MVPower from shore HVDCLight offshore and onshore moduleTransformersUPS and Bender

ProcessFilters, Hydraulic skid, JTValve

Goliat FPSO - Condition Monitoring System

Asset Management System (AMS)

Condition Monitoring of Rotating Equipment

Turbines Compressors and diesel driven generatorsVibration and Performance Monitoring System

Valve MonitoringSmart Instrument MonitoringCondition Monitoring for Static Equipment Metering System MonitoringElectrical Monitoring

Monitoring of the sea cable UPS MonitoringDry transformersOil Filled TransformersCircuit breaker monitoringHeat TracingLow Voltage Switchboards High Voltage MonitoringVariable Speed Drive Monitoring

HVAC MonitoringFire and Gas Detectors MonitoringSub Sea MonitoringMarine Monitoring

Monitoring of the hull structureOffloading StationAnchor WinchesOffshore Cranes

Analyzers MonitoringTelecommunication Surveillance and Monitoring Systems PC, Network and Software MonitoringPerformance MonitoringRotating equipment performance monitoring Loop Performance Monitoring

ABB Asset Management System - Ifea … · ABB Asset Management System ... ABB and 3rd party PLC...

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