ON-LINE INSPECTION IN PHM

Rotating Equipment and Static

Field Operations – PT. Pertamina Hulu Mahakam

 Overview PHM Field Operations Area

CPU
NPU

TUNU SISI
CPU NPU NUBI
TAMBORA

HCA
Tangerang
Lapangan
Gas HANDIL
CPA SISI
Lapangan SPU NUBI
Minyak Cikampek
SPS

CRUDE Bogor BEKAPAI

Balikpapan BEKAPAI
TERMINAL PECIKO
BEKAPAI
SENIPAH

SOUTH MAHAKAM
Sukabumi
METULANG
OIL TANKER
SOUTH MAHAKAM

• 1.5-2 hours with Surfer from SPU to Sisi-Nubi K3S Mahakam 3339 km2

• 45 minutes – 1 hour with Surfer from SPS to Peciko or Bekapai

• 2 hours with Surfer from SPS to SMK
 Simple Diagram: Maintenance Business Process
Know the RIGHT Do the right job RIGHT RIGHT Selection

Identification Planning Scheduling

Spare Pats,
Manufacturer,
Performance contract, etc.
Indicator: Close-out /
Execution
Availability, Reliability, Follow-up
Use Factor. Support

Reliability (Asset Performance Mgt) Performing Maintenance (Work Management)

Service Procurement
• Routine work, non routine,
Technical Authority in Maint. overhaul work, etc.
• ELC, ICS, MEC, MTH Maintenance Material Procurement
Mnt Strategy Evaluation Activities • , outline agreement, etc.
• KPI, Failure consequences, Obsolescence Strategy,
Business Critical Element, etc.
What Who How
Equipment Maintenance
• Proactive maintenance improvement, Performer Type
classification
CMMS & Database Management Level 1 Minor, no tools
Direct impact to Prod. & Preventive Mnt. Time Based, RH based
• CMMS leader, Guardian of MNT procedure Vital
• Optimization program, internal audit, HSE Level 2 Preventive, Predictive
Predictive Mnt. Condition Monitoring, Anomaly based,
Critical Potentially increase risk Level 3 Corrective, Troubleshoot
Support to Site Maint. to Prod. & HSE
• Strategy for revamping work, Corrective Mnt. Notification Based
Level 4 Overhaul, Major repair
• Material management, Spare part procurement Secondary No Impact to Prod. & HSE
control, Level 5 Modification Proactive Mnt. Study Based
• Preservation management, etc.
Overview of Field Operations Facilities 6 77
22
Turbo Compressor
Operational
sites
GTS

(total 360.5 MW ISO rated)

±262,000 ±38,800
Functional Location Equipment

±50,000 ±16,000
12k Field

Work Orders/Year Maintenance Plan 22

Turbogenerator
Transmitter

(total 100.35 MW ISO rated)

±54,000
55 30
Offshore platform
Active Service
Spare Part Items Contracts
MAIN
Facilities and
Equipment
±5000
±600 ~150
Diesel & Gas Engine
24
items Spare Part
Purchased/year Spare Part PO/year
Pedestal Crane (and
Maintenance in NUMBERS >8000 lifting devices)
Overview of Field Operations Facilities
Inspection in NUMBERS

+ 30 CP Survey +1500
KHI & COI/year
+ 360 CC Retrieval/y

 >340 pipelines
 41 ROW (~250 km) +900 Pressure Vessel
 117 River crossing +150 Major inspection/year
>40,000 piping line number
Fundamentals of Machinery Online Inspection in PHM
For rotating machinery, online inspection is Condition Monitoring activities

TECHNOLOGY CONTINUOUS
EQUIPMENT SKILLED PERSONNEL IMPROVEMENT
(SYSTEM & TOOLS)

 Knowledge, Know How Technology, Tools, System

Selection  Certification and IT infrastructure to
 Beneficial,
 Reduce $ (e.g.: reduce
 “Tenaga Ahli” support on-line unpredictable
monitoring breakdown, reduce
unplanned shutdown,
reduce repair downtime,
etc.)

Sensors, Improve
Vital Insource Database efficiency:
Equipment Team (history); IT,
time, cost, …
Digitization 
Digitalization
Condition Monitoring Activities in PHM
Failure Detection requirement:
OSI – PI : SOFTWARE ANALYSIS
 Equipment Operating Data (Pressure, Temperature,
Flow, Vibration, Position, Power, Speed, etc.)
•Performance Evaluation
 Process Data (Fuel Gas, Separator, Cooler, Heater, Well, •Real time monitoring
etc.)

CONDITION MONITORING (manual retrieved) :

 Using handheld (vibration tools, accoustic
measurement tools, etc.) •Vibration Diagnostic
•Theromography
•Accoustic / noise data
CMMS Data (SAP) •Etc.
 Maintenance Statistic Data (WO, date, frequency,
tag number, failure mode, root cause, etc)
SME (Subject • Centrifugal pump and
Matter Expert) compressor overhaul
WORKSHEET (manual Inspection with tools) : • Diesel/gas engine
 Daily reading by operator, oil analysis, overhaul
thermograph, Elc. pro-corona, etc. • HV motor and
 To be converted to electronic-database generator overhaul
• HV busbar PM
 EXTERNAL DATA: (weather, climate, traffic,
• Major repair/overhaul
personnel, overtime, plant condition, etc.) ▪ Turbo machinery lube oil • Spare parts historical
replacement consumption,
▪ Daily reading by operator,
For Incidental ▪ etc 8
Reference Only
Online Condition
Total E&P Monitoring
Indonesie ~ FieldinOperation
PHM: Gas Turbine (via PI-Osisoft)
Gas Turbine is Vital
Equipment in
NPU
Mahakam Operations:

CPU

35 Solar Turbines
SPU

8 GE Aero
Derivatives
CPA

BSP 1 Rolls-Royce
Allison

Gas Turbine applicaton

as Turbocompressor
BPN base

9
Online Condition Monitoring in PHM
Remote real time monitoring (Osisoft – PI)

Trendline (check anomaly, ripple, spike, etc.)

Location: Balikpapan Office

Online Condition Monitoring with Predictive Analysis
1. Use PI Data directly 2. Data processes using excel and analyzed by SME (Subject Matter Expert)

SD setting

Modelling Line AL setting

Turbine Performance

Alert
Expertise
DATABASE

Environment

Operational Condition

GG Exhaust Temperature
Intervention based on On-line monitoring with Predictive Analysis

STEP - 1 STEP - 2 STEP - 3 STEP - 4

On-line Condition Re-confirm and Intervention START UP

Monitoring
Gas Compressor performance was good,
but vibration increased
Planning Set-up
Opportunity work during Planned the Shutdown
available Shutdown window: windows (set up the team,
Boroscope inspection prepare all required material,
other opportunity works, etc.)
Continuous Improvement : On-line Monitoring with Predictive Analysis
IMPROVE AND ENHANCEMENT PHASE-1
Improvement/enhancement on the analysis of
rotating machinery operating data in PI, used for
failure prediction and early anomaly detection
on rotating machinery. This prediction and
detection provide necessary information so that
corrective maintenance can be taken or can be
prepared before further equipment degradation
or failure to reduce the impact on cost and
resources
Maintenance Failures
Consequences

“R-VISION” (Remote-Vision)
✓ Use existing resources (PI, manpower, etc.)
✓ Turbomachinery parameter & running status
✓ Instrument Control ESD Status & Platform
Communication Status
✓ Electrical Status (TEG, GEG, etc)
✓ Email Notification on Turbomachinery Status
Continuous Improvement (continue)
PREDICTIVE FOR PROACTIVE
PHASE-2
MAINTENANCE

✓ Any anomalies on the

turbomachinery will be notified via
email
✓ Online performance monitoring
✓ Enhance Predictive Maintenance

TEAM / TASK FORCE

✓ By Insource engineer (PHM

employee, MEC & ICS engineers)
✓ Already familiar with Company
objective and KPI
✓ Solid and effective team
Prescriptive (from cause
and effect matrix, etc.)
Work Flow Illustration: On-line Monitoring and Predictive Analysis
Historical Data

Know How SME* R-VISION: would

reduce time to
analyze

Equipment

R-VISION:
- combine OSI-PI, Excel,
SAP
- Visualize the PI in CM SME* = Subject Matter Expert
Prescriptive for office
Life data Proactive Maintenance
- Early failure prediction Digitalization over Digitization
FUTURE PLANNING: AI for Enhancement
Historical Data

Equipment

SME* with
SME* = Subject Matter Expert
Knowledge

Life data Digitalization over Digitization

 • Others On-line Monitoring: Instrumentation

Wireless Transmitter
DESCRIPTION
Remote Wells (Well clusters) at CPA and Bekapai offshore
platforms were designed sometimes in 1974 which at that
time no information related wells parameter could be
read/analyze by central control room or Well Performance
Team.

To maximize production potential, wireless transmitter

were installed at well flowlines.
Solution for wireless transmitters were taken with
considerations :
- Remote wells area spread are too wide
- Lack of power generation on remote wells
- No production treatment facilities nearby
179
Wireless
covering 82
Wells
Challenge: Nipah-Nipah
Trees surrounding could
- Installation cost much cheaper compared to SCADA
system
block the signal
transmitter - expandable
 • Others On-line Inspection: FAT (Factory Acceptance Test)

Gas Turbine Overhaul

CRITERIA OF EQUIPMENT
✓ Implemented for gas turbine (GG & HSPT)
REQUIREMENT
✓ Overhaul and engine test is done at OEM
authorized depot at abroad ✓ CONTRACTOR or MANUFACTURE shall have the
✓ No significant finding on engine (i.e.: normal test software which able to share screen online.
overhaul): no vital damage, etc., found during ✓ Stable internet connection
teardown inspection
COMPANY PERSONNEL
CHALLENGE ✓ Have good technical knowledge and competency
✓ Instability internet connection and/or slow
FAT TURBINE of equipment which being tested
internet connection. VIA WEBEX
✓ Good skill for communication in English
✓ Cannot close monitoring the follow up action
in case any abnormalities or findings during
test.
BENEFIT
TIME DIFFERENCE CHALLENGE ✓ Optimization
✓ Big different of time zone (GE in Italy and
✓ Can involve some people with some different
SOLAR in Desoto USA) with Balikpapan Time.
technical expertise
Note: Engine test is done during working hour of
✓ More People for Personnel competency
OEM depot i.e. 10:00 US Central Time, PHM -
development program
Balikpapan 23:00 WITA.
 • Last Online Test : SOLAR Taurus
60 T-7910S (ESN: 1813T)
• Location Turbine Test: Desoto
(USA)
• When: 14 May 20, 10:00 PM –
07:00 AM WITA

• On-line FAT
Gas Turbine Overhaul
• On-line FAT (Factory Acceptance Test) : Electrical
THEG (Thermal Engine Generator)
DESCRIPTION
• Travelling limitation because of Pandemic Covid 19
• FAT of THEG on 23-24 April 2020 (via Zoom & M-Teams)
• Distribution Board and DC/DC Converter on 29-30 April & 22-23
June 2020 (via Webex)
Challenge:
• Network quality:
✓ Video quality is a bit low. Small object/drawing need to take
around 5 seconds to be seen clearly
✓ Audio quality depend on internet connection
• Need longer time to visually inspect a spot (need to direct camera
holder to a specific spot)
Benefit:
• Reduce traveling
• More important meeting/agenda can still be accommodated
• Accessible : time and number of participants
ON-LINE INSPECTION ON STATIC EQUIPMENT
Inspection Business Process Digital Transformation
At which Digital Level are We?

Higher investment for higher gain

Courtesy of R2S.co.uk

Basic Database CIMMS, AIMS,... Augmented Artificial

Reality Intelligence

“Pick the right level to suit the purpose”

ON-LINE INSPECTION ON STATIC EQUIPMENT

Audit
Softcopy submission Of Contractor’s Crane
And Lifting Equipment
MHK-ENTY-SOP-FOP-INS-0065
Remote Visual Inspection
All Contractor’s Lifting equipment has to be audited,
prior to be mobilized to PHM sites, to ensure that
they are fit for service and comply with Regulation
and the standard.
Remote Visual Inspection on Static Equipment

• Acceptable quality of inspection Basic requirement

if basic requirement are met, • Need 4G network,
• No issue with access limitation, • Phone capable for video call ,
• Savings (time, travel, transport), • Personnel/ counterpart with
• Continue after Covid-19, possible “knowledge”,
SOP is being developed
END OF PRESENTATION
BACK-UP Slide
Gas Turbine Population

35 Solar Turbines

8 GE Aero Derivatives

1 Rolls-Royce Allison