Integrity Management of UGS

Vniigaz-Gazprom UGS 2011 – conference Moscow

Winfried Becker, VNG Verbundnetz Gas, AG Leipzig(D)Michael Kaiser, PC-Soft GmbH, Senftenberg (D)

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Topics

Company overview

Integrity Management by

Basic overview

Solutions for gas storage by

Best practice in UGS Management

Case-study –

VNG- Verbundnetz Gas AG

aims, decisions, results, next steps

Conclusion

Modules and benefits of

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UGS facilities of VNG - Verbundnetz Gas AG

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UGS Facilities of VNG - Verbundnetz Gas AG

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Company Profil I PC-Soft GmbH

Software solutions for technical asset management, condition monitoring and maintenance

Headquarter in Berlin - Area

Office Rhine-Ruhr Düsseldorf

More than 1500 user licenses installed worldwide

Business Unit Railway

Business Unit Industry

Business Unit System Integration

Transport

Minerals l Metals l Mining

Oil l Gas l Chemistry

Production l Environment

IT

Infrastructure

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Best practice by PC-Soft

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Topics

Company overview

Integrity Management by

Basic overview

Solutions for gas storage by

Best practice in UGS Management

Case-study –

VNG- Verbundnetz Gas AG

aims, decisions, results, next steps

Conclusion

Modules and benefits of

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Basis Plant Data (component & ínfrastructure)

Operation Management

Service Management

strategic Management

Targets

operations data

Managementknowledge

decisions

Technical data

Investor

Insurance company

Owner

Plant Manager

Strategy , Concepts

Projekts, Methods

Roules for inspections

aims

The global figure

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Plant Asset Management of UGS - general overview

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Dashboard, Cockpit, Info Portal

Dashboard, Cockpit, Info Portal ReportsReports

Global

ASSET

Benchmark

Global

ASSET

BenchmarkForecast

Task, JobsPrognosis and

Renewable StrategyPrognosis and

Renewable Strategy

Abnormality

ConditionDiagnostic

Benchmarking

Diagnostic

Benchmarking

Operation (Opex)Operation (Opex)Cost Classification

Safty-/ Risc-analysisSafty-/ Risc-analysis

Cashflow

ClassificationAvailabilityAvailability

Efficiency / ProfitEfficiency / Profit

Asset Monitoring as a basis – Asset Bentchmark on focus(in accordance to VDI/ VDE 2651)

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Process data& serviceinformation

(Remote) monitoring and analysis of process data and plant condition, initiation of predefined rule-(condition/load) based tasks

Planning, controlling and optimisation of

• preventive,

• corrective and

• condition based

maintenance processes

Optimisation of industrial assets, plant operations, maintenance resources and strategies as well as asset valuation during the complete life cycle

MaintenanceManagement

Condition Monitoring, Tele-diagnosis

Asset/PlantManagement

Condition information

Plant/processknowledge

Managementdecisions

PlantProcess

Continuously improvements

Alarms (notice guidance)

Maintenance requests

Process data archiving

plant and process analysesby engineering staff

Bild 12 reliability

tech

nica

lsaf

ty

index of technical plant safty

index of plant reliability

Integrity Management of UGS

Define Indicators (KPI)

Evaluate current situation

Define improvement strategies

Monitor improvements

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Step 1: Determining relevant plants and componentsGeneral procedure to work on improvement potentials

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Step 3: Analysis of experiences and create asset status parameter

0 bis 40no, rare or often deviation from the targeted condition8 present operating experience

0 oder 20With or without membrane break security device7 safety release valve

0 … 20No accompanying substances, hard or liquid substances with or without filters

6 presence of gas substances

0 … 30 teleservice, tele signalised, locally registered or locally indicating

5 operation monitoring

10 und 20> 0,5 (sub critical) oder <= 0,5 (over critical)4 pressure ratio

0 … 10Static, tumescent or impulsive3 type of load

0 … 10> 30 % resp. < 70 %, 10 to 30 % resp. 70 to 90 % and < 10 % resp. > 90 %

2 condition of the asset in % of the capacity in normal mode

0 … 10< 10 years, 11 to 15 years, 16 to 20 years or > 20 years1 age of the asset/ plant

PointsAttributeCharacter

max. 160 points for y-axis of the risk matrix

General procedure to work on improvement potentials

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Preparatory analysisPreparatory analysis

Data collection and evaluation

Data collection and evaluation

Conclusion and evaluationConclusion and evaluation

Risk matrixRisk matrix

Selection of maintenance strategy

Selection of maintenance strategy

Optimisation of maintenance strategy

Optimisation of maintenance strategy

Tech

nica

l, or

gani

sati

onal

cycl

e

Step 4: decision about maintenance and plant optimisation

General procedure to work on improvement potentials

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Risk of faultDetection Index

consequence of unplaned down-timeSeverity Index (Cost Index)

high

low

low high

corrective Condition based

preventive

condition based

preventive

RCM Strategy

How to find the best MRO strategy?

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MRO Strategy in accordance to DIN 31051

MRO Strategy

KorrektiveInstandhaltung(Ausfallstrategie)

ZustandsabhäInstandhaltung

VorbeugendeInstandhaltung

(Präventivstrategie)corrective condition basedpreventive

Improvement

InstandhaltungInstandhaltung DiagnoseDiagnoseInstandhaltungMaintenance DiagnoseDiagnostic

AnlagenmanagementAnlagenmanagementAnlagenmanagementPlant Asset Management

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Topics

Company overview

Integrity Management by

Basic overview

Solutions for gas storage by

Best practice in UGS Management

Case-study –

VNG- Verbundnetz Gas AG

aims, decisions, results

Conclusion

Modules and benefits of

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UGS management by IWCM

injection and wihtdrawal capacity management

maintenance/ services

Compliance/ reporting

energy consumption

storage capacity

IWCM storagemanagement

UGS management

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DMSDocument Management-

System (GDMCOM )

DMSDocument Management-

System (GDMCOM )SAP PM (VNG)SAP PM (VNG)

SCADA(DCS and EEAS by ELPRO)

SCADA(DCS and EEAS by ELPRO)

Storage Trading (VNG)Storage Trading (VNG)

Energie Trading (VNG)Energie Trading (VNG)

Asset Asset ManagementManagement

System Portex(RWE- ESK)

System Portex(RWE- ESK)

Storage Service

Asset History, Asset Availability

Workforce Management

Storage Operation

Injection and WithdrawalCapacity Management (IWCM)

Cavern Balance Calculation

Energie Load Prognosis 3D-Geo-Simulation (UGS Mittenwalde)3D-Geo-Simulation (UGS Mittenwalde)

IWCM - UGS management at VNG

IWCM

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Cavern CapacityCalculation

Cavern CapacityCalculation

Workforce Management(manual data input)

Workforce Management(manual data input)

SCADA (PLC+CMS)SCADA (PLC+CMS)

External Data (Cavern, Aquifer)

External Data (Cavern, Aquifer)

IWCM cockpit

StorageTrading

Service Manager

Energy Manager

ERP (SAP PM)

ERP (SAP PM)

OperationsManager

OPEX

storage capacity and energy information

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Topics

Company overview

Integrity Management by

Basic overview

Solutions for gas storage by

Best practice in UGS Management

Case-study

VNG- Verbundnetz Gas AG

aims, decisions, results

Conclusion

Modules and benefits of

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UGS BernburgUGS Bernburg

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User Benefits

• Savings in time for legal security switches tests and reports for authority

• Improving of safety by uncovering of incorrect purposes of securityswitches

Highlights

• Recording of all switch operations during the standard operation of the plant

• Plausibility check of switch operations

• Generation of switch operation reports for safety evaluation procedures

check and report of safety equipment

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User Benefits

Processing of inspections, checklists, maintenance and overhaul orders

Access to master data, meter readings and maintenance and overhaul history

On-site acquisition of defect and failure data, measurement values and meter readings

Highlights

Increases quality and productivity of maintenance and overhaul processes

Enables direct on-site access to condition data, maintenance and overhaul history

Facilitates data acquisition on failures, measurement values and meter readings

Permits immediate documentation of all maintenance and overhaul measures

Optimises processing times for maintenance and overhaul procedures

Achieves excellent user acceptance thanks to it's easy and fast touch functionaliy

mobile inspection and maintenance support

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business information & reports

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User Benefits• Optimization of mining operation processes and plants• Identification of bottlenecks and cost drivers in wind machinery• Optimization of maintenance strategies and workforce management• Benchmarking of plants and suppliers

Highlights

• Online processing of operating data and load based maintenance management

• Technical diagnosis of plants and components based on long-time process data

• Condition monitoring of equipments, plants and process lines

• Support of plants and mines benchmarking

Diagnostic and Analysis

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Analysis and Reports

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R&D project: Ejector

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Ejector in operation

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Cockpit UGS Bernburg (VNG)

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zedas®asset cockpit – working gas capacity

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Fault detection by operaionsFault detection by operaionsFault detection by SCADAFault detection by SCADA

Load detectionClassing toolTime based decicions

workorders

message

request

Benchmarking

Dispatching

Fault detection by peopleFault detection by people

Managing faults – doing improvments

E5E4E3E2E1

D5D4D3D2D1

C5C4C3C2C1

B5B4B3B2B1

A5A4A3A2A1

E5E4E3E2E1

D5D4D3D2D1

C5C4C3C2C1

B5B4B3B2B1

A5A4A3A2A1

Reporting

Service Management

Work order management

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Increase of availabilityGuarantee and increase required plant availability by

optimising scheduled and reduce unscheduled downtimes

consolidating, documenting and using plant-related experience and knowledge in order to support decisions

optimising plant performance

Minimise risksMonitor and evaluate plant condition

Support targeted choice/ application of maintenance strategies

trace activities to change stock of assets/ plants and operating modes

zedas®asset – key features

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Minimise costIncrease in efficiency of all activities in terms of sustaining and enhancing assets

Guarantee production efficiency by optimising deployment of external services

Monitor cost development

Increase in operating efficiency by minimising breakdowns/ downtimes

Optimise energy consumptionCollection and analysis of obtained process data in the field of energy consumption

Optimise mode of operation of plants and aggregates

zedas®asset – key features

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Compliance with rulesComply with all technical rules and standards (particularly DVGW G 495)

Verify usage of safety and operating instructions

Comply with technological requirements and operating parameters as well as obtain/ preserve various certificates

zedas®asset – key features

Storage capacity and quality calculationGas delivery from diffenrent explorations

Gas quality parameter different

Ensure constant quality to gas transportation

Reports to authorities

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Topics

Company overview

Integrity Management by

Basic overview

Solutions for gas storage by

Best practice in UGS Management

Case-study –

VNG- Verbundnetz Gas AG

aims, decisions, results, next steps

Conclusion

Modules and benefits of

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zedas asset - modules and add-on

Add-ons

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User Benefits

• High quality workforce management for workshops and service teamsdepending on there needs

• Detecting and avoidance of bottlenecks in service staff, materials andequipment

• Optimization of the service resources utilization

Highlights

• Co-ordination of human resources as well as utilities and tools

• Resources utilization transparency of linked processes

• Visualization as spreadsheets, diagrams or matrices

• Management of technical qualifications and authorizations

Workforce management

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Focus on availability – Stock Manager

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Focus on key figures - LCC/KPI/Prognose - CalculatoR

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Focus on KPI – zedas®asset cockpit

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Reports & Statistik

Standard-Reports

Adhoc-Reports

Office-Integration

Dashboards

Web-Reports

Business Intelligence

Analysis

Asset Management

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Web Portal

Owner InvestorInsuranceOperator ...

PCS-ConnectPCS-Connect

Firma^/Anl. F

PCS-ConnectPCS-Connect

...

PCS-ConnectPCS-Connect

Server

Datenbank

XML

Plant A

PCS-ConnectPCS-Connect

Server

Datenbank

XML

Plant G

PCS-ConnectPCS-Connect

Plant. B

DatendaseDatendase Server

PCS-ConnectPCS-Connect

Service-TeamsExternal Worker

Multiple use of information

Different plants

Type of users

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Our team@work

Any question?

www.pcsoft.de

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Thank you very much!

Don‘t hesitate to contact us in case

of any additional question!

Kontakt

PC-Soft GmbHAdolf-Hennecke-Str. 3701968 SenftenbergGermanyfon +49(35 73) 70 75-0fax +49(35 73) 70 75-19email sales@pcsoft.deweb www.pcsoft.de