汽轮机数字化远程监控的转型历程及关键成功因素

Harris Abd Rahman Sabri
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引用次数: 0

摘要

涡轮机械是公认的油气设施中最重要的设备之一。确定的主要问题是对涡轮机械健康状况的监测;识别设备故障模式;减少计划外维修成本;确保不间断生产,避免计划外停机。因此,需要创新的数字解决方案来解决突出的问题。本文将解释马来西亚国家石油公司上游公司在涡轮机械和主要旋转设备的数字化远程监控和操作过程中所经历的转型之旅。转型之旅始于2014年,当时上游资产部署了各种原始设备制造商(OEM)远程监控解决方案,这需要在现场安装额外的硬件,需要大量的资本支出,并且每个OEM都需要每月订阅。当油价下跌时,这一战略遭遇挫折,需要采取重大的成本削减措施。该资产与卓越运营中心(CoE)合作开发了自己的解决方案,该解决方案被称为规范旋转设备分析(PROTEAN),从长远来看,最终取代了所有OEM解决方案。当马来西亚国家石油公司上游运营卓越团队决定开始数字化之旅时,一切都改变了,他们开发了一种内部预测分析工具,能够识别异常趋势,突出潜在的早期故障,并识别涡轮机械设备可靠性改进的机会。2017年在2台超临界涡轮机械设备上进行了试点实施。在成功实施之后,PROTEAN进行了升级和扩展,覆盖了位于马来西亚境内的23个海上平台,6个陆上终端,国际资产以及世界上第一个浮式液化天然气(即PETRONAS PFLNG Satu)的200多个主要旋转设备。PROTEAN+在支持数据驱动的维护、了解机器劣化率和延长平均大修间隔时间(MTBO)方面提供了优势。PROTEAN+还提供基于每个特定旋转设备的故障模式和影响分析(FMEA)的规定性分析。到目前为止;自2017年以来,PROTEAN已经产生了700多个警报,从而避免了5000万美元的计划外生产延迟和计划外维修成本。该过程还包括技术准备水平(TRL)过程,这对于获得最终用户的信心水平至关重要。最后,本文将重点介绍汽轮机数字化远程监控和操作转型过程中的关键成功因素和关键经验教训。本文就如何在不牺牲技术功能和维持技术能力建设的情况下进一步优化整体运营支出,分享转型过程中的经验。通过了解实施数字化解决方案的关键成功因素,这是一个关于如何在数字化方面构建自己的商业案例并避免创建另一个白象解决方案的真实例子。
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The Transformation Journey and Key Critical Success Factors of Turbomachinery Digital Remote Monitoring
Turbomachinery is recognized as one of the most important equipment in oil and gas facilities. Major issues identified are the monitoring of turbomachinery health condition; recognizing equipment failure patterns; reducing unplanned repair costs; ensuring uninterrupted production and avoiding unscheduled downtime. Thus, there is a need of innovative digital solution to address the highlighted issues. This paper will explain the transformation journey that has been endured by PETRONAS Upstream in crafting the journey in digitalizing the remote monitoring and operations for turbomachinery and major rotating equipment. The transformation journey started back in 2014 where the upstream assets were deploying various Original Equipment Manufacturer (OEM) remote monitoring solutions, which require additional hardware installation at site, significant capital expenditure and monthly subscription for each OEMThe strategy hit a setback when oil price went down which requires significant cost cutting measures. Applying the mantra of "Do More With Less", the asset collaborated with the Centre of Operational Excellence (CoE) to develop their own solution which was branded as Prescriptive Rotating Equipment Analytics (PROTEAN), which eventually replaced all OEM solutions in the long run. Defying the norm, all changed when the PETRONAS Upstream Operational Excellence team decided to embark on the digital journey by developing an in-house predictive analytics tool which is capable to identify anomalies trends, highlight potential incipient failures and identify opportunities for reliability improvement of the turbomachinery equipment. The pilot implementation was conducted in 2017 via implementation on 2 units of supercritical turbomachinery equipment. Following the the successful implementation, PROTEAN was upscaled and expanded to cover more than 200 units of major rotating equipment located at 23 offshore platforms, 6 onshore terminals located within Malaysia, International Assets as well as the world first Floating Liquified Natural Gas i.e. PETRONAS PFLNG Satu. PROTEAN+ provides a niche edge in supporting data driven maintenance, understanding the machinery deteroriation rate and justifying the extension of Mean Time Between Overhaul (MTBO). PROTEAN+ also provides the prescriptive analytics based on the Failure Mode and Effect Analysis (FMEA) of each specific rotating equipment. To date; PROTEAN has generated more than 700 alerts since 2017 resulting in USD50 Million of cost avoidance from unplanned production deferment and unplanned repair cost. The journey also covers the Technology Readiness Level (TRL) process which is vital in order to gain the confidence level from end users. As a conclusion, the paper will highlight the critical success factors and key lessons learned in a transformation journey for turbomachinery digital remote monitoring and operation. This paper shares the experience from the transformation journey on how the overall operating expenditure can be further optimised without sacrificing the technical functionality as well as sustaining the technical capability building. By understanding the key critical success factors in implementing the digital solution, it is a real life example on how to build your own business case when it comes to digitalisation and to avoid from creating another white elephant solution.
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