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PETRONAS ROTATING EQUIPMENT ANALYTICS (PROTEAN) · • Simple visuals whilst providing as much...
Transcript of PETRONAS ROTATING EQUIPMENT ANALYTICS (PROTEAN) · • Simple visuals whilst providing as much...
© 2017 Petroliam Nasional Berhad (PETRONAS) 1
© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
PETRONAS ROTATING EQUIPMENT ANALYTICS (PROTEAN)
Presented by
Khairil Azwan B Khabri – COE Upstream
Gavin Halls – COE Upstream
© 2017 Petroliam Nasional Berhad (PETRONAS) 2
Company Overview
Petroleum Nasional Berhad (PETRONAS) is Malaysia’s fully integrated oil & gas multinational with proven capabilities in a broad spectrum of the petroleum chain value. Establish in August 17, 1974, PETRONAS vision is to be a Leading Oil and Gas Multinational of Choice PETRONAS mission statements are • We are a business entity • Petroleum is our core business • Our primary responsibility is to develop and add value to this
national resource • Our objective is to contribute to the well-being of the people
and the nation
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PETRONAS Core Business
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© 2017 Petroliam Nasional Berhad (PETRONAS)
Initial Problem Statement
Over 130 pieces of gas turbine driven equipment
Numerous manufacturers
Centrifugal Gas Compressor
Generator
30+ Pieces of Super Critical Equipment – single duty high value
Numerous Reciprocating engines and pumps
OEM and 3rd Party solutions mean financial commitment would be considerable
Management directive to go digital
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PETRONAS Maintenance & Engineering team looked at how to perform diagnostics
using unit data on one single unit cost effectively
May
2015
August
2015
Utilized Operation Data Management system
(ODMS) which is a data capture system using handheld data loggers
October
2015
Team compiled monthly
report using running data
and equipment vibration and
lube oil health status
December
2015
Team developed the process
flow and investigated ways to
improve the overall
monitoring system
When did all begin?
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• Unable to run macro to bring data in
from spreadsheet automatically
• Poor data entry by operators
• Numerous errors in data capture
• Manual process to capture data
from ODMS
• Understand data
• Monitoring actual data
• Monthly report was produced
showing health of the unit
• Visualized data
• Captured a few issues
• Understand process flow
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• Not to duplicate machinery HMI
• Not to duplicate the unit control system
• Powerful automatic analytical tools to identify issues before they become issues
• Simple visuals whilst providing as much relevant information to the engineer as possible
• Trends and graphs take human process power to look for issue
• Automated alert system
• Ability to review historical data
• Not limited to Major Rotating Equipment
• Support other disciplines
• Electrical health
• Pumps
• Vessels
• Ability to evolve system
• Visuals
• Algorithms
• Integrate with other systems
ADD Value to PETRONAS
Basic Design Brief
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Lessons Learnt and Limitations
Understanding the need for
management of a system
Excel not ideal as very processor heavy: constant
No automatic email
notifications
Very manual to
understand alerts
Difficult to
integrate into other
PETRONAS
systems
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System Solution Architecture
Workflows
&
Integration
Smart
Visualization
Informed
Decisions
Applications
Data
Management
Data
Sources
Monitoring & Surveillance Analysis & Predictive Action & Optimization
Real Time
Historians
Business Process
Automation Engine Analysis & Predictive
Engines Optimization
Engines
1
2
3
4
5
6
PI System
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Design Brief for next step November 2016
Clear aim on the system to be developed with element
of People, process & Technology
Visuals should be meaningful
System does the hard work and complex thinking
processes
Link with other PETRONAS software solutions
Human to make final decision
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No algorithm
embedded to the
systems
Very manual to
understand alerts
Dashboard
Excel not ideal as
very processor
heavy: constant
Difficult to
integrate into
other PETRONAS
systems
No automatic
notifications
PI Data Archive
PI System
Access
PI AF Notifications
Asset Analytics PI Coresight
How do OSIsoft help PROTEAN
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Early development of PROTEAN
Developed system for 2 critical
gas turbine driven compressor
units
Automatic e-mail notifications of
issues proved difficult and
unreliable. Email notification of
unit shutdown successful
Data points analyzed based on
criticality of data point
Data dump when unit shuts
down to aid RCFA : CSV file on
shared drive
Analytic page simple but
effective
Utilized PETRONAS PI System
for data collection and
algorithms. Utilized PI Coresight
for visuals 01 02
03 04
05 06
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Developed PROTEAN in PI System Environment
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Did it Work?
• Yes • System alerted
to numerous
concerns over a
2 month period
notifications
worked
• Visuals worked
well
• PROTEAN
Dashboard
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During development and implementation May 2017
Increase number of units
covered and ISO 14224
system classification
Multiple data point
comparisons Increase
number of units
covered
Understanding of
PI AF structure
and power
Better email notifications. More
information to recipient. Utilized Event
Frame process
Create templates for algorithm.
Reduce processor and server
loading.
Not all algorithms are required
on all data points
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Current Look and Feel
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PROTEAN as tools in PETRONAS Integrated Operation (IO)
Unit
Review
data and
confirm
issue
Algorithms
runAnalysis output Concerns
Issue initial action or
recommendation to
respective
stakeholders
Critical Trends
shown on IO
Raise SAP
notification
Recommendations will show
Issue
Criticality
Possible solutions
Rectification
carried outConfirmed by data
Monthly Report
Platform Central ICBM Department Regional
Automatic data
from PI
Validation of data
E-mail alert to
relevant parties
Concerns
Improvement in
algorithms
Closing the circle… system improvements
Automatic Process
Closing the circle… system improvements
Initial actions
carried out
Notification
received
Platform
ICBM
Engineer SME
ICBM
Engineer Operations
Maintenance
ICBM
Manager
Plan for
rectification
EIC
If rectification is
required
Human to Human
communicationAutomatic processReporting
Automatic Process
Unit
Automatic data
from PI
Algorithms
run
Validation of data
Analysis output
Critical Trends
shown on IO
E-mail alert to
relevant parties
Concerns
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No of unit in December 2016
PROTEAN in demand !
No of unit in April 2017 No of unit in October 2017
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Next Development
• CMMS, PETRONAS Asset Management, online drawings and other
system integrations
• Further Supercritical and C1 units to be incorporated – 100 + units
by 2019
• Research more complex algorithms and OSIsoft PI System add-on
• Ability for individuals to run reports on equipment and compare
between regions
• Technical Condition Index (TCI) for systems and unit for easy
visualization of equipment health
• Develop fault tree to assist engineers with investigation and
diagnosis of alerts
• Develop risk based maintenance philosophy (condition based) and
move away from fixed periodic maintenance schedules
Next Development
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Summary as of Q3 2017
Evolution rather than
revolution
PROTEAN is
developing very
well and meeting
expectations
270 man hours
each unit to
replicate due to
template system
Low cost and
high return on
investment
predicted
PROTEAN future
upgrades will be
based on benefit
to user
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The Future
Analysis tools
Pattern
recognition
Baseline scoring
Future data -
prediction
Spare part
optimization
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Final Thoughts
Why pay the OEM for Remote
Monitoring and Diagnostics
(RM&D) when the OEM is
receiving all the data for R&D?
The OEM should be paying the
operator for the data… business
model change?
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THE FUN PART IS WE DESIGNED A FANTASTIC LOGO!!!!
Symbolizes the rotating
element Symbolizes the machinery
heartbeat
Trident for
Predictive
Diagnostic
Prognostic
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Khairil Azwan Bin Khabri
Head Reliability Management
Operational Excellence
Center of Excellence
PETRONAS Carigali
Gavin Warren Halls [email protected]
Rotating Machinery Specialist
Operational Excellence
Center of Excellence
PETRONAS Carigali
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Nazrul Hsyraf M Mokhtar [email protected]
PI Specialist
Group Technical Data
Project Delivery and Technology
PETRONAS
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EMEA USERS CONFERENCE 2017 LONDON #OSISOFTUC ©2017 OSIsoft, LLC
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Questions
Please wait for the
microphone before asking
your questions
Please remember to…
Complete the Online Survey
for this session
State your
name & company
© 2017 Petroliam Nasional Berhad (PETRONAS) 27
M Nazori B Janor
Anuar Ismail
M Shahrizal B Jasmani
Shaharuddin Hamid Mustapha
Abayazi B Zainul Zaidah Zainal
Nazrul Hsyraf B M Mokhtar
Azlan B Ayub
Marina Syazlin M Saidi
Erma Fathin Aqera
Syazwani Mohd Ali
Nur Sharafina Md Abidin Shah
Nisa Balqis Masnoor
M Shafek A Aziz
Muhammad Hafizi Mat Saat
A Halim B A Gani
Saharudin B M Rejab
Josiah Tay Guang Wei
Madzalan B Nawi
Siti Zainah Mapak
Nabilah Nur Amanina Abdul Rahim
Shairine Manlosa
Hew Pei Chin
Nor Affendi B Jemidi
Rahmat Nur Adi Wijaya
Khairul Anwar B M Nor
M Faizal B Mohamed
M Hafiz B Husin
Megat Nazri B Hanifah
Muqrim Dzubairy B Shahaimi
M Muslim B Jusoh
Sharizan Ramli
Idris Ibrahim
Musreen Azwan Mustafa
Arif Ibrahim
Khairul Rijal
Gavin Warren Halls
M Farid B M Ismail M Zaha Mira B M Idrus
A Ghaffar Dawam
Hairil Helmy Hamzah
M Fadzly B M Khalil
Sultan Maideen Noorul Amen
Chen Kah Seong
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Thank You
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