risk based maintenance strategy
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Risk Based Maintenance Strategy at NET4GAS
Petr Koutný Head Of Asset Operation NET4GAS, s.r.o.
Copenhagen Denmark
May 13th, 2011
Content
1. History of Czech gas industry 2. NET4GAS, s.r.o. o Transmition grid o Gas flow o Maintenance in N4G
3. Maintenance Strategy Support o 1st step - Pipelines o 2nd step - RBM/CBM for non-pipeline assets using PIMS
modules o 3rd step - Dynamic Asset Simulation - DAS o Goals
4. Ongoing Projects
2
1. History of the Czech Gas Industry
1847 1919
1997 1994
1973
1931 1967
2006
1971
2010
First town gas deliveries from
Prague Gas Works
Foundation of International
Gas Union
Foundation of the Czechoslovak Gas and Water Association
First deliveries of NG through Brotherhood
Pipeline
2002
2011
3
4
2. NET4GAS, s.r.o.
4
New address: NET4GAS, s.r.o. Na Hřebenech II 1718/8 CZ 140 21 Praha 4 – Nusle T: +420 220 221 111
• Part of RWE International Group
• Exclusive holder of license for operation of gas transmission system in CZ
• Providing equal access to gas transmission system for all natural gas traders
• Transmits more than 30 BCM of natural gas per year for international customers, 10 BCM for Czech Republic
• Member of Czech Gas Union or European Association of Transmission System Operators (GTE)
• 15 bil CZK investment to the transmission grid till 2020
Key Figures for 2010 M CZK M EUR
EBITDA 8 246 330
Operation result 5 981 239
Profit before taxation 6 204 248
Profit after taxation 5 026 201
Investments 759 30
Number of employees 519
5
2. NET4GAS Transmission Grid
5
Main activities:
Gas Transport to foreign clients Gas Transport to intrastate customers Maintenance services
Comprises:
Border Delivery Stations 4 BDS In construction 2 Intrastate Delivery Stations 86 Compressor Stations 5 CS Installed Power 297 MW UGS of different operators 9 (with total capacity 3,25 BCM)
Technical Data:
3,640 km of gas line Pressure 4.0 to 8.4 MPa, Diameters up to DN 1400
STORK
2. NET4GAS Transmission Grid
SAYDA
HORA SV. KATEŘINY
WAIDHAUS
Transmission grid 2011
KOUŘIM
KRALICE N. O.
BŘECLAV HOSTIM VESELÍ N. L. MALEŠOVICE
HOSPOZÍN
Border Delivery Station
Compressor Station
ROZVADOV
Junction Point
LANŽHOT
OLBERNHAU
Avg. Gas consumption of CZECH REPUBLIC
cz
cz
cz
cz
cz
cz
Delivery Station
25 mil.m3/d
35 mil.m3/d
35 mil.m3/d
35 mil.m3/d
70 mil.m3/d
95 mil.m3/d
30 mil.m3/d
70 mil.m3/d
180 mil.m3/d
25 mil.m3/d
45 mil.m3/d
93 mil.m3/d
25 mil.m3/d
6
2. NET4GAS Pipelines - Design
Total length 3 640 km Diameters, mostly 20“ - 56“ (DN 500 – DN 1400) MAOP 7.35 MPa, 6.3 MPa, 6.1 MPa, 8.4 MPa ) Material steel (X 52 - X 70) Coating bitumen tape ( in field coating ) factory PE epoxy ( small sections - repairs ) CP (Cathodic protection) all pipelines, permanently, compressor stations without protection NDT testing 100% of welds were tested Ground cover > 0,8 m Safety zone 160 m both sides from pipeline Protected zone 4 m both sides from pipeline
Transit pipelines are 100% piggable and regularly inspected using internal inspection. Intrastate pipelines are mostly piggable as well, condition of unpiggable sections is regularly assessed.
7
2. Maintenance costs by Asset type
8
Pipeline Transit; 69 %; (2460 km)
Pipeline Domestic; 12 %; (1180 km)
Compressor Stations; 15 %; (5 CS)
Delivery Stations Transit; 3 %; (4 DS)
Delivery Stations Domestic; 1 %; (86 DS)
Value by Asset type
Pipeline Transit; 40 %
Pipeline Domestic; 12 % Compressor Stations; 36 %
Delivery Stations Transit; 7 %
Delivery Stations Domestic; 5 %
Maintenance costs by Asset type
2. Maintenance by type
9
Maintenance after Failure
Regular Maintenance
Casing Repairs 3% Cathodic Protection
6% CS - Other Basic
Maintenance 9%
CS - Maintenance 14%
I & C 5%
Internal Inspection 3%
Other Basic Maintenance 17%
Pipeline Inspection 4%
Pipeline Maintenance
20%
Valve Replacement 19%
10
3. Maintenance Strategy Support Asset management in progress
Asset Condition
pipelines PIMS
Asset Strategy
Long-term
Financial plan
Scenarios
OPEX, CAPEX
DAS
Asset Condition
Pipelines Non-pipeline assets Other Assets
PIMS/ RBM/CBM
ILI since 1988 Turbo Sets Diagnostics since 1980
11
194 km 10.307 km
1988 2010
Cumulative Inspected length
year
- Safety and reliability of N4G pipelines is based on reinspections - Maximum inspection interval - 8 years (Czech Gas Standard) - Used MFL & TFI methods in combination with mapping unit - More than 2500 defects repaired in 20 years
3. Maintenance Strategy Support
1st step – Pipelines
PIMS - Pipeline Integrity Management System
Main Sources: Internal Inspections GIS Soil type Crossings Cathodic Protection
Functions: Merge and View data from different sources Defect assessment Risk assessment Repairs planning
194 km 10.307 km
1988 2010
Cumulative Inspected length
year
Participiants: Logica ATP Gasunie
SAP PM
PIMS
3. Maintenance Strategy Support - 1st step
Pipeline Repair Process
Defect assesment, proposed to dig out
Approval of repair
Internal inspection External Inspection
Asset condition data
Infield Defect Assessment and Repair
GIS
Notification
SAP PM order closing
Repair documentation
Plan against
final solution
Protocol saved in DMS
Final Documentation
Link to Protocol
Order
12
13
3. Maintenance Strategy Support
2nd step - RBM/CBM for non-pipeline assets using PIMS modules
Goals: • NET4GAS as a responsible gas transport system operator needs:
• Information on actual status of all assets on transport system regarding their usability for operation (Border and Intrastate Delivery Stations, Turbo sets, Valve Stations, Control Systems, Valves, Other important assets)
• Prediction of life time of individual assets and assessment of their current condition from life cycle point of view (as a basis for decision on maintenance measures and optimization of maintenance plans)
• Reliable information to prove acceptable costs of operation and maintenance for Controlling and Regulatory Objectives
• Assumptions:
• Information shall be provided in functional location hierarchy detail with possibility of aggregation to higher level objects
• Information shall reflect the actual asset status (immediate, long-term) • Information shall be used both for daily operations and maintenance and for
planning of large scale maintenance measures in short, mid and long term horizon
SAP PM
PIMS / RBM / CBM
SAP BI
DAS
14
Notifica-tions
FL - assets
Orders Immediate asset status
Asset condition + proposed maintenance measures
Risk model
Data for assessment
Asset condition
Measures
Plan + costs
FL
Status
Maintenance costs
Condition
Plan + planned costs
Status of open notifications
FL
Operational tool for asset and maintenance
Analytical tool for diagnostics and maintenance
Management tool for operations and maintenance
Asset status
Asset condition + costs
Summary asset information (status, condition, technical + financial data)
Strategic tool of asset management
FL Long-term financial plan OPEX, CAPEX
Other inputs
Long-term financial plan OPEX, CAPEX
Handhelds
FL - assets
GIS
Asset strategy
Long-term financial planning
3. Maintenance Strategy Support 2nd step – PIMS/RBM/CBM for non-pipeline assets Pipeline Integrity Management System / Risk Based Management / Condition Based Management
Architecture of solution
15
Risk decomposition Risk groups Risk factors
Constant properties 35%
Technical condition 65%
Significance 100%
Probability of failure 70%
Consequences of failure 30%
Total risk Age 70%
Risk of technology 30%
Mechanical condition 20%
Internal leak 40%
External leak 40%
Significance for transport 50%
Extra costs of failure 50%
Assessment scheme example
etc.
etc. etc.
etc. etc.
Categories 0 to 10 0
11 to 25 3
over 25 10
V0 leak 0
V1 leak 3
V2 leak 7
V3 leak 10
etc.
etc.
C
weight
score
direct assignment to specific risk segment
3. Maintenance Strategy Support
2nd step - Principles of RBM/CBM method
16
3. Maintenance Strategy Support
2nd step - Asset ranking using risk matrix RBM/CBM
Risk matrix shows distribution of risk related to specific class of assets within the company
Risk is presented as relation of:
– probability of failure – and consequences of failure
100
90
1 1
80
70
1
60
1 3 3 2 1
50
1 1 2 1 1 21 2
40
22 5 1 1 1 1
30
59 52 1 1
20
2
10
0 10 20 30 40 50 60 70 80 90 100
Probability of failure
Con
sequ
ence
s of
failu
re
Risk Matrix 2010 Example: Control systems
Probability of failure [%]
Cons
eque
nces
of f
ailu
re [%
]
Gesamtkosten
0
2
4
6
8
10
12
14
16
18
20
0 10 20 30 40
Mil
lio
nen
€
Simulationszeit (a)
Aktuelle StrategieAlternative Strategie
Gesamtkosten
0
2
4
6
8
10
12
14
16
18
20
0 10 20 30 40
Mil
lio
nen
€
Simulationszeit (a)
Aktuelle StrategieAlternative Strategie
Dynamic Asset Simulation
2010: Lifecycle only partly shown View of the complete lifecycle
Strategy 1
Strategy 2
Strategy 1
Strategy 2
Total expenses Total expenses
2080 2010 2080 2010
Lifecycle Lifecycle
Dynamic Asset Simulation in NET4GAS: - supports to identify sustainable/long-term asset strategies - simulate the mid-term and long-term effects of business decisions - identify the sensitivity of different measures, especially OPEX and CAPEX - quantify qualitative effects and interactions regarding different competitive objectives
3. Maintenance Strategy Support
3rd step - Dynamic Asset Simulation - DAS
17
18 16/05/2011
3. Maintenance Strategy Support
3rd step - Dynamic Asset Simulation - DAS Simulation of OPEX and CAPEX trend
Asset Tree
Asset Distribution according to age and technical status
85 % Good
10 % Middle
5% Poor
0% Critical
19
Optimal Technical Condition
Proactive Maintenance
Asset Planning
Operational Excellence
Safety and Reliability
20
Nord Stream
NEL
OPAL
Gazela
4. Ongoing Projects - Nord Stream – OPAL / NEL – Gazelle A third Route of Russian gas to Europe
Nord Stream NEL OPAL Gazelle
PN [bar] 220 200 170
100 100 85
DN [mm] 1 200 1 200 1 400 1 400
Q [BCM/rok] 55 (2 x
27,5) 20 35 30 - 33
Pipeline Length [km] 2 x 1224 440 470 166
Commissioning [year]
1. 2011 2. 2012 2012 2011 2012
Expected Investment [mil €] 7 400 1 000 1 000 400
Thank you for your attention
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