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Integrity Management of UGS
Vniigaz-Gazprom UGS 2011 – conference Moscow
Winfried Becker, VNG Verbundnetz Gas, AG Leipzig(D)Michael Kaiser, PC-Soft GmbH, Senftenberg (D)
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Topics
Company overview
Integrity Management by
Basic overview
Solutions for gas storage by
Best practice in UGS Management
Case-study –
VNG- Verbundnetz Gas AG
aims, decisions, results, next steps
Conclusion
Modules and benefits of
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UGS facilities of VNG - Verbundnetz Gas AG
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UGS Facilities of VNG - Verbundnetz Gas AG
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Company Profil I PC-Soft GmbH
Software solutions for technical asset management, condition monitoring and maintenance
Headquarter in Berlin - Area
Office Rhine-Ruhr Düsseldorf
More than 1500 user licenses installed worldwide
Business Unit Railway
Business Unit Industry
Business Unit System Integration
Transport
Minerals l Metals l Mining
Oil l Gas l Chemistry
Production l Environment
IT
Infrastructure
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Best practice by PC-Soft
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Topics
Company overview
Integrity Management by
Basic overview
Solutions for gas storage by
Best practice in UGS Management
Case-study –
VNG- Verbundnetz Gas AG
aims, decisions, results, next steps
Conclusion
Modules and benefits of
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Basis Plant Data (component & ínfrastructure)
Operation Management
Service Management
strategic Management
Targets
operations data
Managementknowledge
decisions
Technical data
Investor
Insurance company
Owner
Plant Manager
Strategy , Concepts
Projekts, Methods
Roules for inspections
aims
The global figure
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Plant Asset Management of UGS - general overview
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Dashboard, Cockpit, Info Portal
Dashboard, Cockpit, Info Portal ReportsReports
Global
ASSET
Benchmark
Global
ASSET
BenchmarkForecast
Task, JobsPrognosis and
Renewable StrategyPrognosis and
Renewable Strategy
Abnormality
ConditionDiagnostic
Benchmarking
Diagnostic
Benchmarking
Operation (Opex)Operation (Opex)Cost Classification
Safty-/ Risc-analysisSafty-/ Risc-analysis
Cashflow
ClassificationAvailabilityAvailability
Efficiency / ProfitEfficiency / Profit
Asset Monitoring as a basis – Asset Bentchmark on focus(in accordance to VDI/ VDE 2651)
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Process data& serviceinformation
(Remote) monitoring and analysis of process data and plant condition, initiation of predefined rule-(condition/load) based tasks
Planning, controlling and optimisation of
• preventive,
• corrective and
• condition based
maintenance processes
Optimisation of industrial assets, plant operations, maintenance resources and strategies as well as asset valuation during the complete life cycle
MaintenanceManagement
Condition Monitoring, Tele-diagnosis
Asset/PlantManagement
Condition information
Plant/processknowledge
Managementdecisions
PlantProcess
Continuously improvements
Alarms (notice guidance)
Maintenance requests
Process data archiving
plant and process analysesby engineering staff
Bild 12 reliability
tech
nica
lsaf
ty
index of technical plant safty
index of plant reliability
Integrity Management of UGS
Define Indicators (KPI)
Evaluate current situation
Define improvement strategies
Monitor improvements
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Step 1: Determining relevant plants and componentsGeneral procedure to work on improvement potentials
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Step 3: Analysis of experiences and create asset status parameter
0 bis 40no, rare or often deviation from the targeted condition8 present operating experience
0 oder 20With or without membrane break security device7 safety release valve
0 … 20No accompanying substances, hard or liquid substances with or without filters
6 presence of gas substances
0 … 30 teleservice, tele signalised, locally registered or locally indicating
5 operation monitoring
10 und 20> 0,5 (sub critical) oder <= 0,5 (over critical)4 pressure ratio
0 … 10Static, tumescent or impulsive3 type of load
0 … 10> 30 % resp. < 70 %, 10 to 30 % resp. 70 to 90 % and < 10 % resp. > 90 %
2 condition of the asset in % of the capacity in normal mode
0 … 10< 10 years, 11 to 15 years, 16 to 20 years or > 20 years1 age of the asset/ plant
PointsAttributeCharacter
max. 160 points for y-axis of the risk matrix
General procedure to work on improvement potentials
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Preparatory analysisPreparatory analysis
Data collection and evaluation
Data collection and evaluation
Conclusion and evaluationConclusion and evaluation
Risk matrixRisk matrix
Selection of maintenance strategy
Selection of maintenance strategy
Optimisation of maintenance strategy
Optimisation of maintenance strategy
Tech
nica
l, or
gani
sati
onal
cycl
e
Step 4: decision about maintenance and plant optimisation
General procedure to work on improvement potentials
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Risk of faultDetection Index
consequence of unplaned down-timeSeverity Index (Cost Index)
high
low
low high
corrective Condition based
preventive
condition based
preventive
RCM Strategy
How to find the best MRO strategy?
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MRO Strategy in accordance to DIN 31051
MRO Strategy
KorrektiveInstandhaltung(Ausfallstrategie)
ZustandsabhäInstandhaltung
VorbeugendeInstandhaltung
(Präventivstrategie)corrective condition basedpreventive
Improvement
InstandhaltungInstandhaltung DiagnoseDiagnoseInstandhaltungMaintenance DiagnoseDiagnostic
AnlagenmanagementAnlagenmanagementAnlagenmanagementPlant Asset Management
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Topics
Company overview
Integrity Management by
Basic overview
Solutions for gas storage by
Best practice in UGS Management
Case-study –
VNG- Verbundnetz Gas AG
aims, decisions, results
Conclusion
Modules and benefits of
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UGS management by IWCM
injection and wihtdrawal capacity management
maintenance/ services
Compliance/ reporting
energy consumption
storage capacity
IWCM storagemanagement
UGS management
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DMSDocument Management-
System (GDMCOM )
DMSDocument Management-
System (GDMCOM )SAP PM (VNG)SAP PM (VNG)
SCADA(DCS and EEAS by ELPRO)
SCADA(DCS and EEAS by ELPRO)
Storage Trading (VNG)Storage Trading (VNG)
Energie Trading (VNG)Energie Trading (VNG)
Asset Asset ManagementManagement
System Portex(RWE- ESK)
System Portex(RWE- ESK)
Storage Service
Asset History, Asset Availability
Workforce Management
Storage Operation
Injection and WithdrawalCapacity Management (IWCM)
Cavern Balance Calculation
Energie Load Prognosis 3D-Geo-Simulation (UGS Mittenwalde)3D-Geo-Simulation (UGS Mittenwalde)
IWCM - UGS management at VNG
IWCM
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Cavern CapacityCalculation
Cavern CapacityCalculation
Workforce Management(manual data input)
Workforce Management(manual data input)
SCADA (PLC+CMS)SCADA (PLC+CMS)
External Data (Cavern, Aquifer)
External Data (Cavern, Aquifer)
IWCM cockpit
StorageTrading
Service Manager
Energy Manager
ERP (SAP PM)
ERP (SAP PM)
OperationsManager
OPEX
storage capacity and energy information
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Topics
Company overview
Integrity Management by
Basic overview
Solutions for gas storage by
Best practice in UGS Management
Case-study
VNG- Verbundnetz Gas AG
aims, decisions, results
Conclusion
Modules and benefits of
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UGS BernburgUGS Bernburg
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User Benefits
• Savings in time for legal security switches tests and reports for authority
• Improving of safety by uncovering of incorrect purposes of securityswitches
Highlights
• Recording of all switch operations during the standard operation of the plant
• Plausibility check of switch operations
• Generation of switch operation reports for safety evaluation procedures
check and report of safety equipment
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User Benefits
Processing of inspections, checklists, maintenance and overhaul orders
Access to master data, meter readings and maintenance and overhaul history
On-site acquisition of defect and failure data, measurement values and meter readings
Highlights
Increases quality and productivity of maintenance and overhaul processes
Enables direct on-site access to condition data, maintenance and overhaul history
Facilitates data acquisition on failures, measurement values and meter readings
Permits immediate documentation of all maintenance and overhaul measures
Optimises processing times for maintenance and overhaul procedures
Achieves excellent user acceptance thanks to it's easy and fast touch functionaliy
mobile inspection and maintenance support
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business information & reports
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User Benefits• Optimization of mining operation processes and plants• Identification of bottlenecks and cost drivers in wind machinery• Optimization of maintenance strategies and workforce management• Benchmarking of plants and suppliers
Highlights
• Online processing of operating data and load based maintenance management
• Technical diagnosis of plants and components based on long-time process data
• Condition monitoring of equipments, plants and process lines
• Support of plants and mines benchmarking
Diagnostic and Analysis
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Analysis and Reports
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R&D project: Ejector
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Ejector in operation
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Cockpit UGS Bernburg (VNG)
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zedas®asset cockpit – working gas capacity
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Fault detection by operaionsFault detection by operaionsFault detection by SCADAFault detection by SCADA
Load detectionClassing toolTime based decicions
workorders
message
request
Benchmarking
Dispatching
Fault detection by peopleFault detection by people
Managing faults – doing improvments
E5E4E3E2E1
D5D4D3D2D1
C5C4C3C2C1
B5B4B3B2B1
A5A4A3A2A1
E5E4E3E2E1
D5D4D3D2D1
C5C4C3C2C1
B5B4B3B2B1
A5A4A3A2A1
Reporting
Service Management
Work order management
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Increase of availabilityGuarantee and increase required plant availability by
optimising scheduled and reduce unscheduled downtimes
consolidating, documenting and using plant-related experience and knowledge in order to support decisions
optimising plant performance
Minimise risksMonitor and evaluate plant condition
Support targeted choice/ application of maintenance strategies
trace activities to change stock of assets/ plants and operating modes
zedas®asset – key features
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Minimise costIncrease in efficiency of all activities in terms of sustaining and enhancing assets
Guarantee production efficiency by optimising deployment of external services
Monitor cost development
Increase in operating efficiency by minimising breakdowns/ downtimes
Optimise energy consumptionCollection and analysis of obtained process data in the field of energy consumption
Optimise mode of operation of plants and aggregates
zedas®asset – key features
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Compliance with rulesComply with all technical rules and standards (particularly DVGW G 495)
Verify usage of safety and operating instructions
Comply with technological requirements and operating parameters as well as obtain/ preserve various certificates
zedas®asset – key features
Storage capacity and quality calculationGas delivery from diffenrent explorations
Gas quality parameter different
Ensure constant quality to gas transportation
Reports to authorities
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Topics
Company overview
Integrity Management by
Basic overview
Solutions for gas storage by
Best practice in UGS Management
Case-study –
VNG- Verbundnetz Gas AG
aims, decisions, results, next steps
Conclusion
Modules and benefits of
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zedas asset - modules and add-on
Add-ons
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User Benefits
• High quality workforce management for workshops and service teamsdepending on there needs
• Detecting and avoidance of bottlenecks in service staff, materials andequipment
• Optimization of the service resources utilization
Highlights
• Co-ordination of human resources as well as utilities and tools
• Resources utilization transparency of linked processes
• Visualization as spreadsheets, diagrams or matrices
• Management of technical qualifications and authorizations
Workforce management
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Focus on availability – Stock Manager
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Focus on key figures - LCC/KPI/Prognose - CalculatoR
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Focus on KPI – zedas®asset cockpit
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Reports & Statistik
Standard-Reports
Adhoc-Reports
Office-Integration
Dashboards
Web-Reports
Business Intelligence
Analysis
Asset Management
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Web Portal
Owner InvestorInsuranceOperator ...
PCS-ConnectPCS-Connect
Firma^/Anl. F
PCS-ConnectPCS-Connect
...
PCS-ConnectPCS-Connect
Server
Datenbank
XML
Plant A
PCS-ConnectPCS-Connect
Server
Datenbank
XML
Plant G
PCS-ConnectPCS-Connect
Plant. B
DatendaseDatendase Server
PCS-ConnectPCS-Connect
Service-TeamsExternal Worker
Multiple use of information
Different plants
Type of users
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Our team@work
Any question?
www.pcsoft.de
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Thank you very much!
Don‘t hesitate to contact us in case
of any additional question!
Kontakt
PC-Soft GmbHAdolf-Hennecke-Str. 3701968 SenftenbergGermanyfon +49(35 73) 70 75-0fax +49(35 73) 70 75-19email [email protected] www.pcsoft.de