no slide title · pdf filetotal energy concept system (aga 2011) after: bragg, ... gas export...
TRANSCRIPT
2013 Honeywell Users Group Europe, Middle East and Africa
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From Metering to Diagnostics to Operational Excellence
What is the next step?
Martin Bragg
Honeywell Proprietary
Honeywell.com
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Agenda
• Introduction to Engineered Field Solutions (EFS)
• History of diagnostics in measurement
• From diagnostics to operational excellence
• Honeywell’s EFS vision on the future of metering
Honeywell Proprietary
Honeywell.com
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Integrated Solutions for Better Performance
• Pressure Reduction & Metering Stations (PRMS), incl. City Gates
• Underground storage
• Biogas
• Compressed Natural Gas (CNG) stations
• Turbo Expander (MTG) stations
Gas Solutions
• Tank inventory management
• Loading/unloading skids
• Metering skids
• Terminal logistics management
• ERP integration
• Integrated terminal automation
Terminal Operations
• Alarm and monitoring systems
• Valve remote control systems
• Tank gauging, cargo & ballast
• Loading integration
• Portable ullage temperature interface systems
• Sampling
Marine Solutions
Honeywell Proprietary
Honeywell.com
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Integrated Solutions Across Oil & Gas Supply Chains
PressureReduction
Custody Transfer Metering
DistributedControl System
Simulation Optimization,ERP Software
Fire & GasSystems
SCADA
Gas Processing
Plant
LNG Carrier
LNG Terminal: Receiving
Pipeline Gas Transportation
PowerPlant
LargeIndustrial
Plant
UndergroundStorage
Bio Gas Producer
Power Plant
Pip
elin
e
GAS
Well
OIL Oil Terminal
Oil Tanker
Oil Terminal
Refinery
Transportation Pipeline
Product Terminal
Tanker/ Barge Terminal
Pipeline
Truck/ Rail
ChemicalPlant
ProductRetail
Transportation
Other Industries & Commercial
Well
Security, Surveillance,Access Control
Compressor Station
PumpingStation
City Gate Station
PowerPlant
Commercial Plant
IndustrialPlant
Residential Plant
LNG Terminal: Export
Honeywell Proprietary
Honeywell.com
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The Performance Link
Honeywell’s Engineered Field Solutions links each step of the oil and gas supply chain, start to finish.
• Integrated storage, transport and distribution processes
• Fluid custody transfer, guaranteed compliance and accuracy
• Higher safety, higher security
Performance makes the difference
Honeywell Proprietary
Honeywell.com
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Terminal Operations
• Oil transportation, distribution and storage
• Global service coverage, domain knowledge
• Complete portfolio, wide ranges of technologies
• Custody transfer applications
• Compliance with legal metrology & safety standards
• Terminal automation
• Tank storage, loading, metering skids
• Meter proving
Serving Oil Logistics Worldwide
Better Resources, Better Results
Honeywell Proprietary
Honeywell.com
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Marine Solutions
• Our equipment and marine solutions are sailing on 8,000 ships worldwide
• Global service around the world
• Tankers, bulkers, container ship barges, offshore support vessels
• High tech vessels: LNG, FPSO, FSO
• Cargo, ballast, slop, fuel, fresh water tanks
• Custody transfer applications
Serving Ships Worldwide
Better Resources, Better Results
Honeywell Marine
Honeywell Proprietary
Honeywell.com
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Gas Technology
• Gas transportation, distribution and underground storage
• Global service coverage, domain knowledge
• Complete portfolio, wide ranges of technologies
• Pressure reduction and metering stations
• Custody transfer applications
• Smart metering
Broad Portfolio for the Gas Industry Worldwide
Better Resources, Better Results
Honeywell Proprietary
Honeywell.com
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Metering Principles in Oil & Gas Industry
• Orifice & Venturi
• Orifice on-line, real-time diagnostics available (DPD Prognosis)
• Rotary meters
• Off-line remote diagnostics available from Elster-Instromet
• On-line, real-time diagnostics available
• Condition-based monitoring is a key driver
• Emerson released diagnostic tool for the Micro-Motion meter
Differential Pressure
Positive Displacement
TurbineUltrasonic Metering
Coriolis
Honeywell Proprietary
Honeywell.com
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Evolution of USM Diagnostics
Traditional analog diagnostics with oscilloscope and multi-meter.
Digital diagnostics with meter dashboards like RMG-view, and many other meter diagnostic packages.
Integrated system diagnostics.
The Total Energy Measurement concept is Extended Data Mining
Honeywell Proprietary
Honeywell.com
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Mutually Exclusive Events?
Yes: With Two Different Metering Technologies
Field Verification and Validation of an
Energy Measurement System
after: Herwijn, 2008.
Total Energy Concept System (AGA 2011)
after: Bragg, et al.
GAS METER STANDARD GAS PROPERTY STANDARD
Turbine Meter
AGA 7
Compressibility
SGERG88
ISO 9951 SGERG91
EN 12261 MGERG
Ultrasonic Meter
AGA 9 AGA NX 19
ISO 17089-1 AGA 8
EN 14236 Base Conditions ISO 6976
Orifice Plate
AGA 3
Composition
ISO 6974
ISO 5167 ISO 10723
Conversion Device EN 12405 ASTM 1945
Calorific Value
ISO 6976
GPA 2145
GPA 2172
Speed-of-sound AGA 10
Specific Heat AGA 10
Honeywell Proprietary
Honeywell.com
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Why Diagnostics?
Standards and compliance through type-testing is critical to quality and the minimum entry requirement to market
Ensure accuracy of the operational metering system:
• Prove your metering is accurate throughout its useful life-cycle
• Signal when operational accuracy is affected
• Caused by process condition or metering defect
Honeywell Proprietary
Honeywell.com
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USM Diagnostics – Overall ApproachUSM Diagnostics – Overall Approach
Key Observations
• Most manufacturers provide similar diagnostic methods
• Inference based on various parameters is mostly done by experts
• Inference tools are emerging as key trends, e.g. Artificial Neural Networks
• Enhancing inference engine to reflect clear maintenance action
Tech Trend: Inference Tools for Fault Isolation
• Performs analysis to infer the fault and its source
• Mostly manual
• Early tech trend new method in ANN*
* ANN: Artificial Neural Networks
Inference Engine
• SNR
• VoS to AGA 10
• Asymmetry
• Profile factors
• Swirl angle
• Performance
• Turbulence
Processing(Diagnostics)
• Fluid velocity
• Pressure
• Temperature
• Transit times
• Path velocities
• Delta times
Measurements What is Next?
Honeywell Proprietary
Honeywell.com
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Evolution of Orifice Diagnostics
Traditional diagnostics only for the DP tansmitters. Plates inspected visually.
Now digital diagnostics with a meter dashboard called Prognosis.
Honeywell Proprietary
Honeywell.com
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From Meter to Diagnostics - What’s Next?
What is Next?
Orifice Meter
(Shale Gas)
Prognosis Diagnostics Software
Honeywell Proprietary
Honeywell.com
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Industry Concerns and Challenges
• Increased complexity
• Reducing and aging workforce
• Reduction in operating budgets
• Greater geographic challenges
• Increased need for faster, more precise decision-making
• Stricter compliance on emissions and safety
Our customers under increasing pressure
Need to achieve and deliver in the face of:
• Improve productivity
• Increase yields
• Reduce waste
• Reduce raw material usage
• Maximize utilization of assets
• Minimize energy usage and carbon footprint
• Eliminate safety incidents/process excursions
• Adhere to increasingly stringent HSE, regulatory compliance requirements
Honeywell Proprietary
Honeywell.com
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From Diagnostics to Operational Excellence
Honeywell Proprietary
Honeywell.com
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Oil & Gas Production
Well 1
Well 2
Well 3
Well 4
Well 5
Well 6Oil Export
Metering
Export
Pumps
Sat Field A
Prod Sep
Sat Field B
Prod Sep
M
M
M
M
Water Treatment
Plant
M
M
M
M M
M M
M
Gas Treatment
Plant
Gas Export Metering
Gas Compressor
Fuel Gas
M
M
M
M
M
M
M
M
M
Test Sep
1st Stage
Separator
2nd Stage
Separator
Honeywell Proprietary
Honeywell.com
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Where is My Information?
Valuable information is all around in your plant and compartmentalised
• On-board meter diagnostics
• Process instrument diagnostics
• Flow computers
• Metering supervisory computers
• Process information
Compare with a MIS
• Consolidate all available information
• Valuable insights on how to
optimise business
• Impossible when looking at individual
bits of information
Honeywell Proprietary
Honeywell.com
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What if You Could?
Promote optimal operations while at the same time protecting
your people, the environment and your
reputation?
Solve the challenge of remote operations
and limited expertise?
Overcome ‘analysis paralysis’ and start
making the right decisions at
the right time?
Unleash the knowledge tied up in all your
metering and control components?
Operate at ‘maximum efficiency’
all the time with integrated real-
time data?
Honeywell Proprietary
Honeywell.com
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The Metering Community Changes
• Metering guru
• Lifetime employee
• Experienced
• Plant or remote-office based
• Solid & reliable
Going
Honeywell Proprietary
Honeywell.com
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The Metering Community Changes
• More likely to work from a local support office close to site though able to support from remote locations
• A champion of new technology
• Systems / control engineer capable of using standard interfaces and supporting the platform rather than the device
Now
Honeywell Proprietary
Honeywell.com
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Honeywell’s Vision for the Future of Metering
Honeywell Proprietary
Honeywell.com
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Our Vision
Provide fully compliant metering
Connectivity supporting data integration
Provide real-time analysis tools
Honeywell Proprietary
Honeywell.com
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Compliant Metering Products
• Flow meters: rotary, turbine, ultrasonic
• Flow computers
• Gas analysis
• Electronic volume correctors
• Telemetry
• Data collection and management
Honeywell Proprietary
Honeywell.com
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DCS Embedded Fiscal Metering
MeterSuiteTM
Honeywell Proprietary
Honeywell.com
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DCS Integrated Flow Computation
• Secure Totalisation• Fiscal Accuracy• Reporting• Proving• Sampling• Chromatograph• etc.
MeterSuiteTM
Honeywell Proprietary
Honeywell.com
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Honeywell MeterSuite™ Approvals
MeterSuite™ is fully:
• MID approved
• OIML R117 Approved
• ERCB Directive 017 compliant
All Calculations Meet:
API Standards
ISO Standards
AGA Standards
Honeywell Proprietary
Honeywell.com
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Intuition® Executive
Microsoft®
SharePoint® portal brings together web parts and displays from Honeywell and non-Honeywell systems.
Visualize & act on data from multiple sources
Engage your experts when needed for maximum impact through integrated instant messaging and email
Organize your company’s knowledge to learn from experience with document libraries, task lists and wiki communication tools
Get from data to decision faster with visual key report analysis & diagnostic data
Collaborate across functional silos by integrating data from multiple sources and channels of communication
Enable remote operations & collaboration through online workspaces & meeting rooms
Squeeze more value out of your current investments: bring in data from current systems and infrastructure
Honeywell Proprietary
Honeywell.com
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Anticipate.
Now You Can
Predict problems & identify opportunities in time to act on them
• Visualise and act on data federated from multiple sources
• Organise your company’s knowledge to learn from experience
Collaborate.
Capture knowledge & share information and best practices for smarter, more agile decisions
• Enable remote operations & collaboration
• Engage your experts as needed for maximum impact
• Collaborate across functional silos
Act.
Drive performance with work processes - ensure that knowledge is acted upon
• Get from data to decision faster
• Stop reinventing and start reusing - squeeze more value out of your current investments
Collaborate.Anticipate. Act.
Honeywell Proprietary
Honeywell.com
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Capture Expert Knowledge
• Identify opportunities and avoid problems that previously passed unnoticed
– Avoid significant environmental or safety infractions
• Capture the knowledge of your experts with collaborative tools
– Training junior staff for when experts are unavailable
• Improve personnel productivity
– Searchable information resides in document libraries, wikis
• Tools for the end-user to collaborate with other peers and experts
Honeywell Proprietary
Honeywell.com
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CUSTOMER CHALLENGES: Coal Bed methane
production in Australia, needed to implement a remote surveillance
solution to assess/optimize performance of hundreds of wells;
increase safety and reduce production downtime; and promote
collaboration to increase operational efficiency.
HONEYWELL SOLUTION: Turn-key system
integration, Intuition and Well Performance Monitor solution, data
acquisition solution, data historian, and integration with third-party
systems including a production data management system.
CUSTOMER RESULTS: Anticipated Reduced
production downtime; improved safety via faster identification of
integrity issues; more surveillance with less people; and achieved
an enhanced collaboration.
Customer Success Story
Application: Coal Bed Methane – Unconventional Gas
Result: Project is Ongoing, start up late 2012
Goal: Operational Excellence
Honeywell Proprietary
Honeywell.com
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It started with the meter…
To operational metering excellence bringing together all that has gone before plus a host of disparate systems into one and mining the ‘enterprise’ to enable you to Anticipate, Collaborate and Act!
Operational Excellence in Metering
Progressed to on-board and remote diagnostics• Data archives historian with trends analysis• Artifical Neural Network application to 3D data
Extended to other measurements for confidence• Mutually exclusive events and truth tables• ‘Pay and Check’ metering
Honeywell Proprietary
Honeywell.com
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Summary Conclusions
• The traditional meter manufacturer had to look toward a total solution beyond the meter itself
– To provide a confidence that the operational meter is working within its original design specification
– Developing diagnostics and condition based monitoring
• The manufacturer is moving towards “operational excellence partnering” through extending its systems and data mining with software such as Intuition®
Executive to enable Anticipation, Collaboration and, subsequently, acting rapidly to improve productivity
• Valuable information is often locked within many disparate systems
Partnering in Operational Metering Excellence