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Peter Stock, Executive Director, Sentratech, Seattle,
Washington, USA
22-24 November 2010, Johannesburg
THE ALASKA EXPERIENCE
RELIABILITY CENTRED
MAINTENANCE AND
ONLINE MONITORING USING THE PI SYSTEM
22-24 November 2010, Johannesburg
ABOUT ALYESKA PIPELINE
• 800 miles long
• 48” diameter pipe
• 5 Pump Stations
• Marine Terminal
• 1.4 Million bpd operating
capacity
• Logistics & Operations
centers in Valdez,
Anchorage, and Fairbanks
Brooks Range
Tanana River Bridge Crossing
Valdez Terminal
22-24 November 2010, Johannesburg
Operation Control Center
Background
• Currently running 42 turbines within 6 pump stations
• Pipeline throughput drops from 2.136 million bbpd to
1.1 million bbpd
• High cost of transporting Alaskan crude
• Advances in engineering design
• 2001 Alyeska embarked on a Strategic
Reconfiguration (SR) project
Strategic Reconfiguration (SR)
• Primarily involved electrifying and automating the pump
stations
• Power source at each pump station was changed to
generated power or commercial power
• Project included upgrading all control systems using
PLCs across the pipeline
• SR project reduced the number of turbines to 10 and
the number of active pump stations to 4
Right-of-Way Agreement (ROW)
• Pipeline crosses Federal and State land
• Agreement stipulates that “all physical assets used on
the ROW must a have a maintenance program in place
before the assets are put into service”
• Sentratech invited by Alyeska to develop the
maintenance strategies for all the reconfigure assets
using Reliability Centered Maintenance
RCM – What is it?
Reliability-Centered Maintenance is a process used to
determine what must be done to ensure that any physical
asset continues to do what its users expect in its present
operating context. ~Moubray, RCM II (1992)
� Describe functions, failure modes, causes, effects and
consequences
� Measure Performance, Actuarial Analysis, Failure Data
� Determine appropriate preventative & predictive tasks for
each physical asset
Evolution of Maintenance Strategies
Effectiveness
Efficiency
Reactive
“Break-Fix”
Run-to-failure
Reactive
“Break-Fix”
Run-to-failure
Preventative
Calendar-based
Runtime-based
Preventative
Calendar-based
Runtime-based
Predictive
Model-Based
Learning Systems
Predictive
Model-Based
Learning Systems
22-24 November 2010, Johannesburg
Maintenance Strategy Initiatives
• Mission
� Ensure pipeline reliability and integrity
using advanced maintenance strategies
• Goals
� Proactive vs. reactive maintenance
� Optimize available resources
� Discover new & better ways to operate
• Challenges
� Difficult operating environment
� Complexities of modernization
� Attrition of SME’s
� Pressure to reduce operating costs
� Increasing scrutiny and regulation
Systems Analyzed
• Safety integrity pressure protection system (SIPPS)
• Booster pump building
• Manifold building
• Fuel systems
• Crude pressure relief systems
• Siemens turbo generators
• Commercial power supply
• 2.25 MW standby generators
• Control module
• Mainline pump set
• Remote gate valves (RGVs)
March 7 – 10, 2009 San Diego, CA, USA
Remote Gate Valves (RGVs)
SCADA
PI
Smart Signal
EQUIPMENT DIAGNOSTICS AND
RESOURCE CENTER (EDRC)
Discrete
Maintenance
Alarms
Reactive
Discrete
Maintenance
Alarms
Reactive
AF/ACE Calculated
Alarms
Condition-Based
Monitoring
AF/ACE Calculated
Alarms
Condition-Based
Monitoring
ACE/AF Calculated
Events
Condition-Based
Monitoring
ACE/AF Calculated
Events
Condition-Based
Monitoring
Maintenance NetworkSCADA Network
Equipment
Warnings
Predictive
Equipment
Warnings
Predictive
Automated PM
Completion
Work OrderScheduling
WORK MANAGEMENT
CorrectiveWork
Orders
All Asset
Backlog
Preventative
All Asset
Backlog
Preventative
Operational
Instrument
Data
Operational
Instrument
Data
High Resolution
Instrument
Data
High Resolution
Instrument
Data
Maintenance Strategies in Action
RESULTS
The EDRC has demonstrated tremendous value:
� Centralized access to equipment and system diagnostics
� Automating 200+ Calendar/Runtime-based PMs
� Facilitating new Condition-Based Monitoring (CBM) algorithms
� Providing post mortem and root cause analysis on equipment failures
� Communicating initial equipment diagnostics with Operations Engineering, OCC,
Field Maintenance, and other SMEs
� Assisting field maintenance with troubleshooting and validating corrective actions
taken in the field
� Reducing intrusive maintenance impacts
� Preventing unintended shutdowns and equipment outages
TANGIBLE BENEFITSEDRC BENEFIT ANNUAL
SAVINGS
Regulatory Calendar-based PM Automation
DOT Valve Strokes – Reduced Field Man-Hours $400,000
Function Testing of Valves – Reduced Field Man-Hours $100,000
DOT Relief Valve Testing $50,000
Tank Level PM’s $35,000
Continuous CBM and PBM Algorithms
Unplanned Downtime Avoidance $350,000
Device Deviation Monitoring – Reduced Field Man Hrs $150,000
FIRST YEAR ANNUAL SAVINGS $1,085,000
22-24 November 2010, Johannesburg
Questions ??
Peter StockP.O. Box 11754
Bainbridge Island, Washington 98110
USA
+ 27 829233646
