Transcript of Plant of the Year 2015 - Fieldbus FoundationIn this slide you can see a comparison between units...
October, 18 2016, Rotterdam
信頼性に基づくアセット管理 Plant of the Year 2015
- Gábor Bereznai -
Plant of the Year winners in 2010
2
規模は小さいが…
ロゴのサイズは会社の売り上げに比例
3
プレゼンター
プレゼンテーションのノート
Let us see the operation area of MOL DS. What distingushes us from a multinational corporation like Shell? In a nutshell: Our achievements in the areas of: Mechanical availability (Solomon) Maintenance cost indicators. (Solomon) Process Safety performance (PSM) Our safety performance last year was free of any accident. How did we achieve all this? One of the key factors was our organisation’s innovative spirit. What do I mean by that? We changed over from corrective approach to preventive and predictive maintenance and implemented on-line condition monitoring systems for rotating, static eqipement and instrumentation and process control. MOL small in the world but,
東欧地域では盤石
4
6 生産ユニット
23 mtpa 精製能力
2.1 mtpa 石油化学製品の生産能力
2000以上のフィリングステーション
プレゼンター
プレゼンテーションのノート
But strong in the region. Here you can see this map about the our sales directions, and the product slate covers from the fuels to the chemical products. MOL has four refineries and two petrochemical sites. I come from the DR which is the flagship refinery of MOL group.
UPDT: 予想外のダウンタイム(計装起因) FIMS: フィールド計装メインテナンスシステム Field Instrumentation Maintenance System Source: MOL SAP-PM Maintenance System, 2014
[ 607 kEDC ]
[ 563 kEDC ]
プレゼンター
プレゼンテーションのノート
In this slide you can see a comparison between units witch equipped with Field Instrumentation Maintenance (FIMS) System and where there are no FIMS at all. The size of the units are more or less the same expressed in kEDC (kilo Equivalent Distillation Capacity). MOL has executed many reliability improvement action since 2008, but we reached the biggest benefits where FIMS were introduced. This was a quantum leap in the Refinery life. You can see the difference were we utilize FIMS there are smaller amount of production losses doe to instrumentation malfunctions comparing the units where FIMS not exists.
7
保護階層
DCS systems
Definition of Group of Assets to
Maintenance
Master Asset Database
Maintenance planning and
sheduling
Maintenance execution
Evalution of Operative
Maintenance
Field Instrumentations
Risk evaluation and handling(Asset Policy)
Asset Strategy Evaluation
Detailed Reliability analysis
Seria
ldi
gita
l co
mm
.
Strategy optimisation
Statical equipements
Corrosion database
Vibration data collection
Risk Based Inspection
Vibration diagnostic, Oil analysis, Thermo
Control Valve and Instrumentation
diagn.,
Rotating machines
Computerised Maintenance Management Systems
Maintenance StrategyCreation
Data Collectors
Equipements
Condition Monitoring Systems
Reliability analysis
(MTBF, MTTR)
Failure modes
On-
line,
di
agno
sti
c
Off-
line,
dia
gnos
tic
On-
line,
di
agno
stic
Off-
line,
dia
gnos
tic, C
omm
unic
ator
RFI
D /
PDA
Off-
line,
dia
gnos
tic
戦略の最適化
資産戦略評価 詳細な信頼性分析 リスク評価、運用 メインテナンス対象
資産の定義
マスタ資産 データベース
メインテナンス計画、 スケジューリング
メインテナンス実行 維持管理の評価 信頼性分析 MTBF、MTTR
装置
データ収集
状態監視システム
メインテナンス 戦略立案
コンピュータ保守 管理システム
8
AMS DM + AMS FIMS servers
FIMS (AMS/PRM) user/expert
SAP-PM server
SAP-PM user
Refinery Information System
DC MUX
On-line FIMS subsystem
(AMS)
Intelligent instrumentations of the DC units
アラームのフィルタリングSAP-FIMS interface
CFV-087
予測通知によりユニット停止時間を避け、7k-700kUSD(約80万〜8000万円)を節
約することができる
CMMSインテグレーション
プレゼンター
プレゼンテーションのノート
But how is this system works/ when in use? Let me explain it with an example: Say,/ one of the control valves gets stuck. In this example you can control it/ in opening direction/ without any problem. But/ when it comes to closing,/ it is faltering./ Nothing can be seen from outside/ until/ the diagnostic system detects/ stress in the valve. A warning is sent to… system/, and so/ it is escalated to the level/ where the responsible people/ perform the RBWS/ and take a decision,/ based on the consequence and probability of the occurrence of a failure and on the maintenance strategy/ applied to the given equipment/, a decision about which notification is serious, which ones can be postponed and which ones do not need any attention at all. Thank god,/ that decision making is very easy/ becasuse 95%/ of all the automatic notifications/ from the system/ are well grounded and can be readily accepted.
In the next few minutes i would like to highlight tha fact that implementing a maintenance system does not really change the maintenance activities in merits. The poperly configurated equipment, setting the maintenance systems as well as taking the advantage of SNAP-ON applications by a highly qualified staff are all of great importance.
12
システムに必要な構成要素
アセット管理システム (AMS, PRM, FDM)
オンライン機器の種類
機器の追加、コンフィグレーション
アラート設定 / 操作
バルブ診断
圧力伝送器校正
分析装置校正
トレーニング
プレゼンター
プレゼンテーションのノート
In the next few minutes i would like to highlight tha fact that implementing a maintenance system does not really change the maintenance activities in merits. The poperly configurated equipment, setting the maintenance systems as well as taking the advantage of SNAP-ON applications by a highly qualified staff are all of great importance.
There are 3 main maintenance systems at Duna Refinery, further on there are 5600 online instruments in 19 units. The availability of the instruments is provided by continuous condition monitoring, automatic ticketing system (to SAP), and preventive-proactive maintenance.
14
オンライン機器の種類 - Transmitters
- Pressure
- Differential pressure
- Level
- Temperature - Flow transmitter
- Valves
- Control valave
- ON-OFF valve (with positioner)
機器ベンダ:29社 機器の種類:157種類
プレゼンター
プレゼンテーションのノート
The complexity of reaching a well-functioning system depends on a great number of diversified insturments. -> The number of the main device types and the actuators further is incresed if we classify them for manufacturers, types, and revisions. -> In our system there are 29 manufacturers, 157 device types, and many many revisions. It will play an important role when we start setting the Alerts, and one of the most important action – the fine tuning.
In a refinery there are many units that are hydrogen consumers, like desulphurization or conversion units. Since the hydrogen can not be stored or buffered the Hydrogen Production Plants are critical units for refinery operation. In these units the pressure swing adsorbers are purifying the hydrogen, therefore any failure of these assets can stop the whole unit and thus affect the refinery production. These adsorbers are operating in a cyclic process, the valves have to open and close 9-10 times in an hour while the pressure level is around 30 bar. Due to these conditions, the loss caused by the failures of these valves was above one million USD in three years. To eliminate this loss and support strategic availability targets we needed a solution to increase reliability of PSA valves.
アーキテクチャ 構成要素の役割
PI Server • プロセスデータベース
• プロセス情報のオンライン分析
• アセットの健全性の計算 – アセット状態 – 運転時間 – パフォーマンス
• ユーザインターフェース – PI Coresight – PI DataLink
SAP PM
• メインテナンスデータベース
• メインテナンスプロセスの管理
• 作業指示書、通知の作成
• アセットの健全性に基づく保守戦略のトリガ
接続 (WebLogic)
計算によるアセットの
健全性
保守関連情報
プレゼンター
プレゼンテーションのノート
To schedule the preventive maintenance we need raw process data and calculations, analyses to turn it into information about asset health. The main process database is the PI Server with the capability of running complex analyses, so we have selected this system to do the online calculations. It is also quite beneficial in PI System, that we can use the well known user interfaces like PI Coresight or PI DataLink. To manage the preventive maintenance we utilized the SAP PM. The activities and asset information are stored here in the Technical Database and Task Lists. The Maintenance Plan can trigger the activities based on Measuring Point values. To make the whole architecture complete we had to develop the middleware. The functionalities of this middleware are to move asset health information into SAP Measuring Points and to move maintenance related information into PI System to prevent duplicated order generation.