© Marc Roussel / Total

Remote Assistance, Intervention and Diagnosis (RAID)

For Rotating Machines

Amélie PESQUET and François JOUANNA

 AGENDA

 Monitoring objectives
 How does Smart Signal work ?
 Where we are with SmartSignal
 Notable “catches”
 Smart Signal Deployment in TOTAL E&P
 Questions

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 AGENDA

 Monitoring objectives
 How does Smart Signal work ?
 Where we are with SmartSignal
 Notable “catches”
 Smart Signal Deployment in TOTAL E&P
 Questions

7th International Gas Turbine Conference 14-15 October 2014 Brussels

IMPROVE CONDITION BASED MAINTENANCE TO AVOID SURPRISES

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 E&P’S FLEET OF TURBOMACHINARY

TOTAL Turbo Machines fleet cumulated power

TOTAL E&P fleet through SmartSignal
5 000
126

4 500

4 000

3 500 OPCOs
64
3 000 54
Operated 46
2 500

22
2 000 17

1 500

1 000

500

A constantly growing fleet in 329 turbine and electrical

number and in size (4524 MW) driven equipment (>1MW)

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 MONITORING OBJECTIVES
Between 2006 and 2010, we recorded several critical rotating machinery
failures having led to substantial production losses and flaring.

71 breakdowns on Gas Turbines

- 22 breakdowns (31%)

34 breakdowns on -Centrifugal Compressors

28 breakdowns (82%)

Among 105 breakdowns recorded, half of them could have been avoided
with a proper remote monitoring and condition based maintenance

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 MONITORING OBJECTIVES
Availability and reliability figures have improved during the past years, but
have plateaued.
Availability Reliability
100.00%

90.00%

95.00%

94.89%
93.52%

92.88%
92.68%

91.84%
80.00%

91.61%

91.37%
90.49%
89.41%
88.98%

86.71%

70.00%

60.00%

• Efforts shall be taken to achieve Total E&P objectives:

– Decrease production shortfall
(by Increasing availability up to 95%, reliability up to 97%)
– Reduce OPEX (Operational Expenses)

SMARTSIGNAL ONE OF THE KEYS TO SUCCESS

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 AGENDA

 Monitoring objectives
 How does Smart Signal work ?
 Where we are with SmartSignal
 Notable “catches”
 Smart Signal Deployment in TOTAL E&P
 Questions

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 WHAT IS AN « EARLY WARNING » DETECTION ?

SmartSignal provides the earliest warning of impending failures on any equipment months in advance
EQUIPMENT CONDITION

Events and minor deviation

Machinery protection Alarm

Machinery protection trip

Functional Failure

OPERATING LIFE

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 HOW BASICALLY SMARTSIGNAL WORKS ?

Example with a centrifugal pump driven

by a variable speed electrical motor
monitored with 2 parameters :
- Speed of the electrical motor
- Flow through the pump
Speed

Time
Flow

Historical data Time

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 HOW IN REALITY SMARTSIGNAL WORKS ?

Traditional Single Sensor with an alarm or trip level

Axial
position

Early Warning Period

Smart Signal real-time, multivariate analysis

Axial
position

Gas
pressure

Speed

Bearing
temp.

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 AGENDA

 Monitoring objectives
 How does Smart Signal work ?
 Where we are with SmartSignal
 Notable “catches”
 Smart Signal Deployment in TOTAL E&P
 Questions

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 PILOT MILESTONES
ALWYN (4) KHARYAGA (4)

ABK (5)

GIRASSOL (14)

CANADON ALFA (2)

DALIA (4)

KICK OFF PILOT ON SITE GIRASSOL GO OTHER ASSETS LICENSE AND END OF PILOT
IT ACCESS
PROJECT TRAINING LIVE GO LIVE CONTRACT SIGN PROJECT
10/2012
07/2012 11/2012 11/2012 02/2013 06/2013 06/2013

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 WHERE ARE WE WITH SMARTSIGNAL TODAY ?
ALWYN (4) KHARYAGA (4)

ABK (5)

GIRASSOL (14)

CANADON ALFA (2)

DALIA (24)

53 shaft lines (146 pieces of equipment) with more than 4000 sensors are
currently monitored with SmartSignal

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 UNIT BREAKDOWN REVIEW ON PILOT FLEET
ALWYN (4) KHARYAGA (4)

ABK (5)
33 shaft lines in the pilot

GIRASSOL (14)
CANADON ALFA (2)
DALIA (4)

2006 2010 04/2013 Today

23 breakdowns on Gas Turbines 0

15 breakdowns on Centrifugal Compressors 0

38 breakdowns were recorded from 2006 to 2010 on the pilot fleet. Since the
start of the Smart Signal pilot, combined with technical and operational
improvements, none have reoccurred.

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 CURRENT SMARTSIGNAL PROCESS

Issue is closed Site data collection,

integration and transmission

Affiliate provides Smart Signal

feedback and takes models
corrective action

Email & Weekly Direct Calls

RAID analyzes issue and

The report is sent to the creates a report
affiliate

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 SOME KEY FIGURES

Since April 2013, on the 53 shaft lines monitored :

 Between 10 and 50 new alerts per day triggered by SmartSignal,
reviewed by Level 1 analyst.
 216 reports reviewed and validated by Level 2 expert analyst sent to
Affiliates.
 153 of which were followed up with further action. (called « catches »)

Others
2%
Performance
17%
Instrumentation
Mechanical
44%
37%

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 EXAMPLE OF WEEKLY REPORT (20 MAY 2014)

Some notable “catches” :

• On Injection/Export gas compressor : Fault on the primary seal gas system.

• On Gas Turbine: Increase of the wheelspace temperature.

• On Gas Turbine: Loss of a feedback on the nozzle guide vane position.

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 AGENDA

 Monitoring objectives
 How does Smart Signal work ?
 Where we are with SmartSignal
 Notable “catches”
 Smart Signal Deployment in TOTAL E&P
 Questions

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 DGS CATCH

Isolation of a Dry Gas Seal supply that could lead to major breakdown.

DRY GAS SEAL

 Early warning allow maintenance

to monitor and act.
 Unplanned shutdown could have
a major impact on gas production
– 1 week of lost of production.

7th International Gas Turbine Conference 14-15 October 2014 Brussels

TURBINE INTER-WHEELSPACE THERMOCOUPLES

● Replacement of the GG
on GE recommended
planned maintenance
with new GG presenting
higher wheelspace
thermocouples (still well
below alarm).

● Unit was shutdown and

replaced.
● The increase in inter
wheelspace temperature
would have led to a trip of
the unit within 3 months –
2-3 weeks of lost of
production

7th International Gas Turbine Conference 14-15 October 2014 Brussels

TURBINE NOZZLE GUIDE VANE FEEDBACK

● Lost of the feedback on

the nozzle guide vane
position.
● The control unit cannot
modulate the load of the
turbine.

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 AGENDA

 Monitoring objectives
 How does Smart Signal work ?
 Where we are with SmartSignal
 Notable “catches”
 Smart Signal Deployment in TOTAL E&P
 Questions

7th International Gas Turbine Conference 14-15 October 2014 Brussels

 ROADMAP FOR SMARTSIGNAL DEPLOYMENT

• CLOV
• DALIA • ARGENTINE
• PAZFLOR
• GIRASSOL • CONGO • ITALIE • GABON
• MOHO
2014 •
•
AKPO
UK
2015 • YANGA 2016 •
•
MYANMAR
TEPNG
2017 • PAYS BAS
• RUSSIE
2018 • TUPNI
• QATAR
• AMENAM
• ABK • NORWAY
• LAGGAN

329 shaft lines (950 pieces of equipment) with more than 35000
sensors will be monitored with SmartSignal at the end of 2018

GLOBAL BUDGET OF THE PROJECT : 20 M€

7th International Gas Turbine Conference 14-15 October 2014 Brussels

7th International Gas Turbine Conference 14-15 October 2014 Brussels
DISCLAIMER AND COPYRIGHT RESERVATION

The TOTAL GROUP is defined as TOTAL S.A. and its affiliates and shall include the person
and the entity making the presentation.

Disclaimer
This presentation may include forward-looking statements within the meaning of the Private
Securities Litigation Reform Act of 1995 with respect to the financial condition, results of
operations, business, strategy and plans of TOTAL GROUP that are subject to risk factors
and uncertainties caused by changes in, without limitation, technological development and
innovation, supply sources, legal framework, market conditions, political or economic events.
TOTAL GROUP does not assume any obligation to update publicly any forward-looking
statement, whether as a result of new information, future events or otherwise. Further
information on factors which could affect the company’s financial results is provided in
documents filed by TOTAL GROUP with the French Autorité des Marchés Financiers and the
US Securities and Exchange Commission.
Accordingly, no reliance may be placed on the accuracy or correctness of any such
statements.

Copyright
All rights are reserved and all material in this presentation may not be reproduced without
the express written permission of the TOTAL GROUP.

7th International Gas Turbine Conference 14-15 October 2014 Brussels