Predictive Asset Analytics: The Future of Maintenance

Major Overhauls (MOH) of major Rotating Equipment is an essential activity to ensure equipment and overall plant's productivity and reliability requirements are met. This submission summarizes Maintenance cost reduction and MOH extension benefits on an integrally geared centrifugal Instrument Air (IA) compressor through a first of its kind Predictive Maintenance (PdM) solution project in ADNOC. Appropriate planning for Major Overhauls (MOH) in accordance with OEM, company standards and international best practices are crucial steps. Digitalization continues to transform the industry, with enhancements to maintenance practices a fundamental aspect. Centralized Predictive Analytics & Diagnostics (CPAD) project is a first of its kind in ADNOC as it ventures into on one of the largest predictive maintenance projects in the oil & gas industry. CPAD enables Predictive Maintenance (PdM) through Advanced Pattern Recognition (APR) and Machine Learning (ML) technologies to effectively monitor & assess equipment performance and overall healthiness. Equipment performance is continuously assessed through the developed asset management predictive analytics tool. Through this tool, models associated with the equipment were evaluated to detect performance deviation from historical normal operating behavior. Any deviation from the historical norm would be flagged to indicate condition degradation and/or performance drop. Moreover, the software is configured to alert for subtle changes in the system behavior that are often an early warning sign of failure. This allows for early troubleshooting, planning and appropriate intervention by maintenance teams. Using the predictive analytics software solution, an MOH interval extension was implemented for an integrally geared centrifugal IA compressor installed at an ADNOC Gas Processing site. The compressor was due for MOH at its traditional fixed maintenance interval of 40,000 running hours in Nov 2019. Through this approach, the actual performance and condition of the compressor was assessed. Its process and equipment parameters (i.e. casing vibrations, bearing vibrations, bearing temperatures and lube oil supply temperature/pressure, etc.) were reviewed, which did not flag any abnormality. The compressor's performance had not deviated from the historical norm; indicating that the equipment was in a healthy condition and had no signs of performance degradation. With this insight, a 15 months extension of the MOH was achieved. Furthermore, a 30% maintenance cost reduction throughout the compressor's life cycle is projected while ensuring equipment's reliability and integrity are upheld. A total of 7 days maintenance down time including work force and materials planning for the MOH activities was deferred. The equipment remained in operation until its rescheduled date for MOH. Through the deployment of predictive analytics solutions, informed decisions can be made by maintenance professionals to challenge traditional maintenance practices, increase Mean Time Between Overhauls (MBTO), realize the full potential of a plant's process & utilities machinery and optimize operational costs of plant assets.

Enhancing Indoor Air Quality and Tackling COVID - 19 Virus

Objective/Scope One of the main concerns of Oil & Gas Plants and associated Buildings is how to improve indoor air quality (IAQ) and tackling viruses. IAQ can be affected, or may become under high risk by some of nearby gases, microbial contaminates or energy stressor that affect the HSE condition. This paper presents the main factors that been considered to provide practical solutions to achieve high IAQ and tackling viruses (such as COVID-19). Methods, Procedures, Process IAQ refers to the air quality within and around the plants/buildings. IAQ can usually be affected, or may become under high risk by nearby gases, particulates, microbial contaminates or any mass that affect 100% HSE. Inadequate air quality in building will increase the risk and impact on transferring viruses to people (such as COVID and Flue) and equipment performance (such as equipment failure, components corrosion and short circuits on control board). Survey and data was recorded to evaluate air quality performance in atmosphere instead of assuming it. Accordingly, the impact of inadequate IAQ was studied and evaluated. Results, Observations & Conclusions The international standard set a good IAQ in respect of gas concentration and human who works inside buildings in a way that less than 50% people should not detect any odor, 25% should not experience discomfort, 10% should not suffer from mucosal irritation and 5% should not experience annoyance. Study concluded that inadequate IAQ inside the building will affect people performance/health and installed equipment performance. In addition, improper HVAC system operation will be become breeding site for odor causing mold and bacteria, specifically on cooling coil. Hence, several technics were studied to improve IAQ, by installing Ultraviolet (UV) light to stop growing bacterial inside the HVAC system, installing chemical filter in air intakes to remove atmospheric dust, gases and bacteria by 100%, upgrading filtration efficiency to MERV-13 or highest achievable to capture at least 75 – 95% of airborne particles between 0.3 and 1.0 micron, increase outdoor air ventilation and temperature/humidity control. The performance of HVAC system and quality of air inside building were monitored by simulating IAQ based on ISO 16890, filters life cycle, energy consumption, and the results were found 100% satisfactory and provided solutions that are now successfully implemented in all new and some of the existing buildings. Novel/Additive Information There are several buildings with similar issues and these approach/technics now being adopted in new constructed/existing buildings to protect human and asset integrity, which will support ADNOC Way by sustaining safe environment operation, lower health risk, reduce of equipment failure, reduce maintenance cost and 100% HSE. There are numbers of occupied buildings across the world were surrounded by aggressive gases/pollution with poor IAQ and above approaches it can be followed to realize larger benefits.

Impact of Increasing Mechanic Competence through Competence Based Curriculum to Improve Product Support Performance in Leading Indonesian Heavy Equipment

The availability and readiness of heavy equipment depends on the level of product support. Product support as after sales service is important for customers to ensure that heavy equipment purchased is always ready for use and produces optimal production. Leadtime and mechanic speed in solving problems that occur in equipment and the so called On Time in Full Solution (OTIF Solution) affects the usability and productivity of equipment. Performance OTIF Solution affects Product Support Performance, and this affects the level of customer satisfaction. The development of mechanic competencies through competency-based training and problems in the field with reference to the Special Work Competency Standards is a strategy to increase the ability and speed of mechanics to solve problems that occur in machines in order to get good OTIF Solution performance. This research aims to determine the impact of increasing competence. mechanic through training with a competency-based curriculum on product performance support. This research was conducted by providing training with the blended learning method with training modules for machines with under-target OTIF Solution performance. The results showed that after mechanics received training, the OTIF Solution increased from the previous 2 years. namely 89% and 88% below the target of 90% to 93%.

Equipment Performance, Costs and Constraints of Packaging and Transporting Rice Straw for Alternative Uses to Burning in the “Parc Natural l’Albufera de València” (Spain)

Rice straw is a residue that causes significant environmental problems, as burning it causes CO2 and ash emissions, while buried waste can cause issues associated with eutrophication. The extraction of straw from fields for alternative uses may contribute to solving these problems, but research into its economic viability is necessary. The straw can be used for crop mulching, biofuel, bedding for livestock, and so on. In this study, we analyse the work carried out by straw harvesting machines (rakes, balers, bundlers, and loaders) and calculate the costs of packing, road-siding, and transportation of the straw from the rice fields to stockage points in the producer area, as well as to locations outside of the rice production area, in order to assess the viability. The costs of all elemental operations were calculated. The costs of all the operations included between raking and unloading in the producer area stocking point ranged between 28.1 and 51 EUR t−1. These costs were compared with the price of rain-fed cereal straw (wheat and barley), which is the most abundant, noting that the years in which rain-fed cereal straw reached high prices, rice straw could serve as a competitive product; however, in years when the former is cheap, it would be necessary to subsidise the harvesting of rice straw.

On Small Scale LNG Concepts

The different economics of small scale LNG plants put more emphasis on capital expenses over process efficiency, and thus favors simpler refrigeration cycles. We typically find reverse Brayton cycles, or SMR (Single mixed refrigerant) cycles. These cycles have specific requirements to the compression equipment, and typically have smaller drivers, either electric drives or gas turbines. The relationship between output, driver size, and process preferences is explained. The type of compressors, and expanders needed are discussed, together with thoughts and the driver preferences. This includes the different control methods that can be used, both for the cycle adaptation, as well as the related control of the compressors, expanders, valves and drivers. Equipment performance maps are created to highlight the required different operating conditions. This result allows for subsequent optimization discussions.

New technologies for well testing and hydrodynamic well study were appliedfor the first time

This article is concerned with the application experience of cutting-edge technology for surface and downhole well testing equipment which is used while well test operations and hydrodynamic well study. The results of operations and equipment performance are presented as well as recommendations on technology application at offshore and onshore projects.

Implementation of Automatic Dust Detector on Dust Suppression System on Transfer Tower 0 In Paiton 9 Power Plants

<p>The operation of dust suppressor and dust collector was operating semi-manually by pressing the power button on the local panel during the initial unloading of coal material from the barge or stockpile, where local operators manage several large areas. This research is carried out on the implementation of Automatic Dust Detector for Dust Suppression operational at Paiton Unit 9 power plants with the aim of increasing the efficiency of operator and equipment performance. We use House of Quality (HOQ) as a determinant of the priority scale for technical response to be implemented, namely the addition of an Automatic Dust Detector. The results obtained showed a decrease in the calculation of the dust suppression operating time, i.e. from 5 hour 54 minutes to 5 hour 6 minutes, from 1005,36L/barge to 869,04L/barge for water consumption, and 1L/barge to 0,86L/barge for chemical use. Furthermore, the implementation of the Automatic Dust Detector can significantly increase efficiency at least 15% from operating time difference. </p>