holistic coordinated optimisation for shipping

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Holistic Coordinated Optimisation for Shipping

Andrew [email protected]

MARINTEKResearch Director

Department of Maintenance TechnologyTrondheim, Norway

Predicting the way forward in Ship Operation

A pre-project proposal

MARINTEK Seminar at NorShipping; 10 June 2009.

2

Outline: other industries c.f. shipping; -

a pre-project proposal

Oil & Gas industry challenges and constraints

Integrated Operations / E-Field / Smart-Field

Center

for Integrated Operations in the Petroleum Industry

Summary; Oil & Gas

Shipping industry challenges and constraints

Management, monitoring & improvement principles

Examples from other industries

Shipping; Collaboration & Remote support -

TOCC

Summary; Shipping

Holistic Coordinated Optimisation for Shipping;

Research Pre-project proposal

After the Research Pre-project

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Oil

& Gas facilitiesChallenges

& constraints:

•Physical

isolation

/ weather

/ seasons•Communication•Reliable condition

monitoring

data•Data analysis

and trending

capability•Maintenance

not optimised•Optimising

production

and overall recovery•Maximising

production

availability•Monitoring

and KPI’s

for continual

improvement•Up-turn

/ down-turn

in business•Shortage

of

experienced

competent

staff•Age profile

of

staff•HSE•Corporate

image•Profit

4

Oil

& Gas; Operation

& Maintenance As is (industry

heritage, where

we

are

coming

from

)

5

Valuation

of

potential

for ”Operation

and Maintenance”

through

IO

32% is Operations(15%) and Maintenance(17%), i.e. NOK

96 billion

(US$

15 billion)

6

Integrated Operations / E-field / Smart-field -

a convenient high-profile enabler for improved maintenance

…covers much

more than

just ”operations”

To facilitate:-

communication

of

information

-

between

people

and organisations

(geographically spread)-

shared

situational

awareness

in order to achieve

better, faster

decisions.

It involves:Man (People), Technology

& Organisation

(MTO)

Applicable

to:Oil

and Gas, Medicine, Shipping, and much

more …….

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Center

for Integrated Operations in the Petroleum Industry www.ntnu.no/iocenter

NTNUSINTEF

IFE

Oil Companies Suppliers

Conducts research, innovation and education within the IO field, to promote accelerated production, increased oil recovery, reduced operating costs and enhanced safety and environmental standards.

CRI –

Centre

for Research-based

Innovation

PROGRAM 1Drilling and well

construction

PROGRAM 2:Reservoir

management

and production

optimization

PROGRAM 3:Operation

and maintenance

PROGRAM 4:Integration

across

disciplines

http://www.ntnu.no/iocenter

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Data processing

Sensor technologyand automation

Visualization

Geographically dispersed teams

Wearable computing

Smarter decisions

RESEARCH CHALLENGES FOR INTEGRATED OPERATIONS

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Failure detection methods on static “Oil & Gas”

equipment offshore

Detection Method % contribution to detection of failure

Casual observation/ unknown 60-65 %

Periodic preventive maintenance 10-15%

Continuous condition monitoring 10-15%

Inspection 5%

Other (production interference, on demand, functional testing etc.)

5-10%

10

Oil

& Gas facilities: Operation

& MaintenanceChallenges

& constraints:

•Physical

isolation

/ weather

/ seasons•Communication•Reliable condition

monitoring

data•Data analysis

and trending

capability•Maintenance

not optimised•Optimising

production

and overall recovery•Maximising

production

availability•Monitoring

and KPI’s

for continual

improvement•Up-turn

/ down-turn

in business•Shortage

of

experienced

competent

staff•Age profile

of

staff•HSE•Corporate

image•Profit

Vendor: rotating

machines

Subsurface

team: reservoir

Production

/ Maint

team

11

Summary –

Oil & Gas

Data sharing & and remote decision support

will lead to

Increased safety & integrity, reduced emissions

Increased life time of the equipment

Increased process regularity

Decreased operation & maintenance costs

Better, smarter, faster decisions

Monitoring of critical parameters should be dominated by continuous or periodic condition monitoring, and not casual observations by personnel

Required Technology

is available (and used on exception basis), but often still not specified in Philosophies / Tenders as required by company

Man

and Organisation

aspects are at least as challenging as Technology

The costs

due to periodic shutdown and/or decreased efficiency should

be emphasised and highlighted

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Oil

& Gas; Operation

& Maintenance To be (successful)Alarm

Alert

OK

Safety/integrity

Availability

Technical

Condition

Index

Integrated

Operations:• High

profile

enabler

(O&M; 1/4 of

the

limelight!)

• Shared

situational

awareness

• Decision

support

• Better, faster decisions

and optimisations

• Hence; -

Improved

production, recovery, integrity

and HSE!

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Center


Summary; Oil & Gas





TOCC

Summary; Shipping




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Shipping: Operation


& constraints:

•Physical

isolation

/ weather

/ seasons

•Communication

•Reliable condition

monitoring

data

•Data analysis

and trending

capability

•Maintenance

not optimised

•Optimise

operational

efficiency

/ fuel

consumption

•Maximise

time at sea

/ Minimise

off-hire

•Monitoring

and KPI’s

for continuous

improvement

•Up-turn

/ down-turn

in business

•Shortage

of

experienced

competent

staff

•Age profile

of

staff

•Health, Safety

& Environmental

impact

•Corporate

image

•Profit

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Additional challenge; priorities of stakeholdersRoles:

Ship-owner

Ship-operator

Ship-manager

Charterer

Cargo Owner

(Ship-broker)Contracts:

Voyage Charter

Time charter

Bareboat charter

Demise charter

Affreightment

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Collaboration

& remote

support The

principles

discussed

here

have been

known

for 20 years

The

following

key

aspects

have recently

changed, making application

of

the

collaboration

principles

more realistic

now:

high capacity wireless communication near the coast and ports(gives new possibilities c.f. high cost satellite systems)

wireless onboard LAN(permit use of handheld equipment supporting communication)

Further developments planned wrt

satellite coverage

The potential advantages for shore based support and optimisation services must be evaluated

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Center


Summary; Oil & Gas





TOCC

Summary; Shipping




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Management, monitoring & improvementPrinciple:

That

which

you

don’t

measure,You

can’t

control.

That

which

you

don’t

control,You

can’t

improve.

Parameters (and required

frequency

for monitoring):Targets for the

year

Targets for the

month

Targets for a series of

voyagesTargets for one

voyage

19

planact

check do(monitor)

(correct)

Management, monitoring & improvement

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Most people

can

now

recognise

that

management

systems are

a cyclic

process, or loop:

ISO 9000

ISO 14001

If

any

of

the

elements in the

cycle

are

missing, the

loop is incomplete, the

system doesn’t

work!

Measurement, analysis

and improvement

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Management, monitoring & improvementMost people

can

now

recognise

that

management

systems are

a cyclic

process, or loop:If

any

of

the

elements in the

cycle

are

missing, the

loop is incomplete, the

system doesn’t

work!

Norwegian

Petroleum Directorate

Maint. Mgt.

PDO Contract

Management

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The

table

is now

simplified

to key-words

only, and colour

coded.

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Center


Summary; Oil & Gas





TOCC

Summary; Shipping




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The required technology and some of the possible functionalities are already available and proven.

The

following

industries

have developed

and successfully

applied these

principles:

Hydro-electric

power

Oil

and Gas

Military/Defence

& Aviation

Space

Medical

care, e.g

”Norsk senter for telemedisin”

Power

generation

& distribution

Railways

others

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Hydro-electric

power

Collaboration

and Operation

Centres

Offshore

Integrated

Operations

Remote

operation

Operation

support centres

Military

Network-based

warfare

Effect-based

warfare

Space

Control Centre

Integrated

logistic

support

JSTARS NETCENTRIC WARFARE (Courtesy

116th ACW)

http://www.km.kongsberg.com/

http://www.dlr.de/

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Center


Summary; Oil & Gas





TOCC

Summary; Shipping




27

Improve competence and tools for utilisation of

technical operational data in the maritime industry

An example

of “collaboration”

in shipping

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Data communication:Fibre optic cable? Oil & Gas; real-time data in real time

Satellite communication? Automatic data transmission as required

Satellite communication? Periodic e-mail with .xml data files

Other?

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TOCC project

OFFICE

SHIP

Feedback

Registration

Main engine performance

Auxiliary engine performance

Hull and propeller performance

Infrastructure

Support

User meetings

Management

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Indexing fleet performance

Alarm

Alert

OK

Ship

Supe

rinte

nden

tFl

eet M

gr. Technical performance

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TOCC procedure

•Develop forms•Input ship static data•Send forms to ship

•Install forms•Input measure data•Form validate data•Data sent to TOCC

•Receive xml/email•Validate data•Store data•Analyze data•Generate report•Send report to ship•Send report to office

•Receives report•Maintenance

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Keys to success

Selection and maintenance of instrumentation

Procedures for performance tests

Quality control of practise versus procedures

Feedback and corrective actions

Follow-up of deviations –

responsibility and support

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TOCC examples

Improvement at fleet level

Improvement at detail level where corrective action can be recognised

36

Examples from RAF project

Reporting on environmental data

Faster response on reports to crew

A basis for learning

Better feedback

More information

Compare with others

Direct communication shore -

vessel

Less information via inspector

Easier to share knowledge

37

Shipping: Operation


& constraints:

•Physical

isolation

/ weather

/ seasons

•Communication

•Reliable condition

monitoring

data

•Data analysis

and trending

capability

•Maintenance

not optimised

•Optimise

operational

efficiency

/ fuel

consumption

•Maximise

time at sea

/ Minimise

off-hire

•Monitoring

and KPI’s

for continuous

improvement

•Up-turn

/ down-turn

in business

•Shortage

of

experienced

competent

staff

•Age profile

of

staff

•Health, Safety

& Environmental

impact

•Corporate

image

•Profit

38

Summary –

Shipping

Many of the Shipping challenges are similar to those in Oil & Gas

The justification is apparent for a trend towards:

Remote monitoring, shared awareness, decision support, KPI’s

Data sharing &

and remote decision support

could lead to

Increased safety & integrity, reduced emissions

Increased life time of the equipment

Increased process regularity (Maximise

time at sea

/ Minimise

off-hire)

Decreased operation & maintenance costs

Better, smarter, faster decisions

Monitoring of critical parameters should be dominated by continuous or periodic condition monitoring, and not casual observations by personnel

Required Technology

is available (and used on exception basis), but often still not specified in Philosophies / Tenders as required by company

Man

and Organisation

aspects are at least as challenging as Technology

The costs

due to periodic shutdown and/or decreased efficiency should

be emphasised and highlighted

39





Center


Summary; Oil & Gas





TOCC

Summary; Shipping




40

Holistic Coordinated Optimisation for Shipping; Research Pre-project proposal:

Together

with

stakeholders & interest

groups, identify:

Candidate

parameters / drivers for evaluation

HSE

Emissions and thermodynamic performance of equipment

Mechanical performance of equipment (monitoring & support)

Performance Indicators for key parameters (KPI’s)

Logistics, routing, port arrival & departure

Competence Development & Competence Assurance

and possibly other parameters such as trim, hull condition etc.

Feasibility

Requirements

for key

decisions, frequency

of

info required

Costs, and potential

value

creation

for each

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Holistic Coordinated Optimisation for Shipping; After the Research Pre-project:

Entirely

dependent on

outcome

of

pre-project; could

be

Further

development

of

necessary

enablers?

Industry

pilot project?

Strategic

research

project?

CRI (Centre

for Research-based

Innovation)?

Critical

questions

for success:

How

good

do we

want

to be?

Where

is the

potential

for improvement?

Can

we

estimate

its

value?

How

good

can

we

be?

holistic coordinated optimisation for shipping

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