Condition Monitoring Data To Onshore

BP Forties - First producing North Sea field, Onshore control via telemetry Abandoned due to limited data and speed of communications BP Milller - Excel Based CM with 10 parameters sent onshore OIL Majors started worrying about Network Security most/all North Sea links closed. North Sea Fibre, rolled out to BP Forties 2001. Linked to Norway for Backhaul to the UK (redundant link) North Sea comms easily available and realtively cheap, widespread Data to Desktop Condition Based Monitoring

Intro

A brief history to CM in the offshore environment How CM works in the offshore sector High regulatory framework and high expectations Overview of System Live Demo

Condition Monitoring

Offshore/Onshore
Simple Visual checks Handheld readings taken, recorded in notebooks Handheld via PDAs Handheld Downloads to Onshore Data Onshore subject to Data Mining Offshore Data sent directly onshore Offshore Data reviewed and maintenance based on Data

Regulations

DSEAR stands for the Dangerous Substances and Explosive Atmospheres Regulations 2002. Dangerous substances can put peoples safety at risk from fire and explosion. DSEAR puts duties on employers and the self-employed to protect people from risks to their safety from fires, explosions and similar events in the workplace, this includes members of the public who may be put at risk by work activity.

Regulations

PFEER regulations (1995) for offshore installations for the Prevention of Fire and Explosion and Emergency Response. They came into force 20th June 1995. They are law in the UK. In summary these regulations state the person or company responsible for an installation is also responsible for protecting persons on the installation from fire and explosion and securing effective emergency response.

Regulations

The Offshore Installations (Safety Case) Regulations 2005 Safety Case requires all MAH ~(Major Accident Hazards) be indentified and controlled. MAH Lead to Performance Standards ~ Performance standards to SCE (Safety Critical Elements) ~ SCE to Individual SIL (Safety Integrity Levels) ~(Other compliance routes are available). SIL sets a PFD ( Probability of failure on Demand ) SIL is from 1e-1 to 1e-3. Using failure rates (Lamda D) and test intervals a PFD is calculated. Not testing within a short period is likely to lead to failure to meet a SIL. Condition based maintenance is a challenge for SIL

Nexen Equipment Condition Monitoring

Condition Based Monitoring (CBM) system that is integral with the Maintenance Management System and aligns to the Nexen Reliability Management Policy. The CBM program centres around the ability to perform machinery diagnostics and proactive condition monitoring remotely. Onshore monitoring and diagnostics centre sited in the Nexen Aberdeen office with access to a wide range of data types. Bringing the relevant data to experts for rapid analysis, avoiding expensive & time consuming mobilisation of personnel & equipment.

Asset Equipment Condition Monitoring System1

Power Generation Equipment

Process Compressors

Pipeline Compressors

Air Compressors

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Vertical Pumps Pump Sets Other Assets Heat Exchangers

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Dynamic vibration data and process variables

Proactive Operations & Maintenance Actions

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Smart Decision SupportSM software screens incoming data Monitoring and Diagnostic Center

Proactive Advisories Early detection of anomalies

Operations, Maintenance, & Engineering

24/7/365 Dedicated Expertise Field-experienced diagnostics engineers

Asset Equipment Condition Monitoring System1

System1 High Criticality Machines (30 machines)
Vibration (amplitude, frequency and phase), temperature and process data from installed transducers continuously recorded and monitored by System1 Thermodynamic performance calculated every 30 seconds and compared with manufacturers stated performance values. Corrections made for ambient and site specific conditions (gas composition changes, etc) Dry Gas Seal monitoring on all centrifugal compressors Machine run hours continuously recorded by System1 Decision Support RulePaks continuously analysing available data for a range of machine specific faults

System1 Balance of Plant (~150 machines)

Vibration (amplitude & frequency), bearing temperature and process data measured periodically using a portable data collector and uploaded to System1 database. Machine run hours continuously recorded by System1

Asset Equipment Condition Monitoring System1

System1 Other Assets & Functionality
Heat exchanger performance monitoring Corrosion monitoring utilising installed transducers Production and availability data Leaks and weeps monitoring PEMS - real time turbine exhaust gas emissions monitoring utilising model data and thermodynamic calculations

Asset Equipment Condition Monitoring System1

Total Exceptions Raised During Last 12 Months - 139

Level 1 Low: Level 2 - Medium: Level 3 - High: removed from Instrument Fault: the Fault requires corrective action. Not likely to result in immediate equipment failure. Incipient fault, which is likely to result in equipment failure. Significant potential to cause loss of production if fault is not rectified or equipment service immediately. Instrument fault which may result in equipment shutdown/lost production if not rectified at earliest opportunity.

Condition Monitoring Thermography Program Thermography

Routine Thermographic surveys to monitor temperatures across rotating equipment Routine Thermographic surveys to identify incipient faults on electrical switchgear Routine Thermographic surveys of process equipment to help identify such things as heat exchanger fouling, passing valves, etc

Offshore Reliability Technicians formally trained in Thermography data collection and analysis. Flir hardware and analysis tools utilised and data stored in System1 using Docuview function

Asset Equipment Condition Monitoring Thermography Program

Total Exceptions Raised During Last 12 Months - 43

Asset Fluid Analysis

Fluid Analysis
Routine sampling of lubrication, fuel and seal fluids to monitor condition and to identify contamination and degradation Database available on-line to monitor trend data and recommendations

Asset Equipment Condition Monitoring Fluid Analysis

Total Exceptions Raised During Last 12 Months - 43

Asset Equipment Condition Monitoring Electrical Techniques Electrical Techniques

Periodic Partial Discharge testing of critical machines utilising installed Rogowski coils to monitor stator condition Periodic Rotor Current Waveform analysis of critical motors to monitor rotor condition Feasibility to connect electrical relays (GE MultiLin) to System1 for continuous real time motor rotor current signature analysis UPS condition monitoring system

Asset Equipment Condition Monitoring Electrical Techniques

Electric Motors - Rotor Current Analysis Number of machines tested: 31 1 Exception (no invasive action required) Electric Motors - Partial Discharge Analysis Number of machines tested: 24 4 Exceptions (no invasive action required)