Increasing Productivity Efficiency and Speed for Midstream Applications

Transcription

1 Increasing Productivity Efficiency and Speed for Midstream Applications Moderated by Dora Adamo GE Oil & Gas, Senior Growth Initiatives Leader

2 Use of Data Management & Digital Technologies for Pipeline Integrity Report prepared for GE Oil & Gas Kimberlite International Oilfield Research KIMBERLITE is a trademark of Kimberlite, LLC

3 Summary of Findings Pipeline companies which take a proactive, data-based approach to integrity management: Experience higher levels of reliability and lower costs due to downtime and reduced throughput Have lower integrity management and maintenance costs Are more likely to place high priority on enterprise data management

4 ANNUAL PER MILE IMPACT ($$) AVERAGE DAILY IMPACT ($$) Reliability is improved by a Proactive, Data Driven Approach $3,000 ANNUAL PER MILE IMPACT ($$) ANNUAL DOWNTIME DAYS $2,197 $2, Days $1, Days $249 $ Days $0 REACTIVE APPROACH PLANNED/ SCHEDULED MAINTENANCE APPROACH PROACTIVE/ DATA DRIVEN APPROACH Prepared for GE Oil & Gas by KIMBERLITE International Oilfield Research

5 Lower Maintenance Costs for a Proactive, Data Driven Approach PLANNED COST UNPLANNED COST $3,000 $2,000 $1,274 (47%) $704 (35%) $1,000 $267(22%) $1,433 (53%) $1,314 (65%) $935 (78%) $0 REACTIVE APPROACH PLANNED/ SCHEDULED MAINTENANCE APPROACH PROACTIVE/ DATA DRIVEN APPROACH

6 Satisfaction w/data Mgmt & Analysis Tools SATISFACTION PRIORITY FOR IMPROVEMENT ABILITY TO INTEGRATE DIFFERENT TYPES OF DATA SETS AVAILABILITY/ ACCESS TO HISTORICAL, INSPECTION & OPERATIONAL DATA PREDICTIVE ANALYTICS FOR EQUIPMENT/ ASSET MAINTENANCE DATA ANALYSIS FOR THREAT ASSESSMENT & RISK MANAGEMENT PIPELINE LIFECYCLE COST MODELING QUALITY OF ILI OR EXTERNAL INSPECTION DATA EASE OF REPORT PREPARATION FOR REGULATORY COMPLIANCE QUALITY OF AUTOMATICALLY COLLECTED OPERATIONAL DATA

7 Prioritization of Enterprise Data Management HIGH PRIORITY MODERATE TOTAL SAMPLE 52% 24% 7% 17% PROACTIVE/ DATA DRIVEN 75% 6% 19% PLANNED APPROACH 39% 36% 7% 18% REACTIVE 50% 50% 0% 50% 100%

8 Midstream Digital enablement

9 Midstream- Digital to transform pipeline challenges Data management gaps Siloed data sets and lack of access to key historical inspection/operational data... disjointed and not effective decision making Production Missed throughput... support decisions on pipeline production schedule Customer Challenges... that digital can transform into opportunities Costs High costs... aged infrastructure, over maintenance and incident, high spare parts inventory levels, low efficiency due to configuration, demand and operation constraints Safety / Reliability Lack of comprehensive risk/safety management system including pipeline integrity management Customer KPIs 17 potential (up to) 2020 (up to) Reliability 1% 3% Costs 5% 20% Throughput 0.5% 2%

10 Midstream Digital journey to achieve max outcomes 3 Plant View Facility-level products Non productive time Reliability... upto 3% Production Optimization Throughput... upto 2% Process Optimization Maintenance Costs... up to 20% Cloud solutions and services 2 Asset-specific Asset-specific products Dynamic data integration Predictive analytics Automated defect recognition Automated risk management Performance and health suite CBM on-line & residual life estimators 1 Get Connected Data collection Instrument layer Sensor local layer data Analog devices (data) Smart devices (data + HART) Vibration Data layer Central Analytics data layer Historian HMI graphic pages BN System1 Controls layer Mark Vie BN 3500 Opticomp Controls layer Predix GE s software platform for the Industrial Internet Confidential. Not to be copied, distributed, or reproduced without prior approval.

11 Example of applications for O&G Customers PRODUCTION Challenge #3: Support decision making Tier 1 Rotating Equipment performance advisory + optimization COSTS Tier 2 Pipeline capacity optimization: what-it modelling to evaluate operation safety/integrity - Predix Digital Pipeline Challenge #2: Reduce costs by 20% SAFETY / RELIABILITY Tier 1 - CBM on-line, IICS and additional sensors for residual life on rotating equipment Tier 2 Adopt a risk-based approach to maintenance strategy: Meridium on the whole gas pipeline station Challenge #1: Reduce Average Yearly incidents Tier 1 Predix platform for data management + integration to simplify threat management for operators, generating outcomes to proactively manage assets Tier 2 Integration of asset inspection data from Design to Decommissioning, increasing accuracy of models + reduction in incidents linked to asset failures

12 We re transforming service

13 GE Oil & Gas Smart Helmet A digital tool providing GE Oil & Gas Field Service Engineers with a more effective connection to Engineering experts Applicability Planned outages with GE FSE GE Resident (&/or RM&D) Unplanned event with no GE personnel at site* Connectivity with remote or complex sites* *Virtual Express Care A new service employing Smart Helmet to enable direct access for Customer site reps to OEM Engineering expertise Customer Benefits Saving on unplanned up to 50% Faster troubleshooting Direct access to OEM Eng OEM engineering knowledge is now just a click away

14 Engine pool concept for Nova + LMs/PGTs families GE Engine POOL Added Value Reduced spare asset need % Turn Around Time vs. Std engine repair Returned Engine Refurbished Engine Tech Injection at each shop visit with latest Service bulletins Engine Engine Engine Engine No scope creep, risk absorbed by GE Repair Shop Network Kollnes,Norway Plant 1st Outage 2nd Outage Houston, USA Massa, Italy Doha, Qatar Aero Level 4- Aero Level 2 NovaLT Level 4 Petropolis, Brazil Subang Malaysia

15 NovaLT *16 Engine Exchange Concept Complete engine inside package Gas Generator or HP* Module Power Turbine or LP* Module = + *HP High Pressure LP Low Pressure 1) HP Module Exchange 2) Full Engine Khrs Improving Customer Outcomes Simplified outages using Aeroderivative maintenance philosophies Reduced outage duration vs traditional on-deck maintenance in Heavy-Duty GT GE Repair Shop processes ensure high quality results, engine 100% tested before shipment Engine Exchange is the keystone of maintenance for NovaLT GT family * Denotes a trademark of the General Electric Company

16 LT16 Maintenance Services Planned Maintenance Contractual Services Range HP Module MOH MOH MOH MOH LP Module / MOH / MOH [K FFH] Alternate HP or complete HP/LP module swap Guaranteed A/R, Turnaround time (shared maintenance risk) Partecipation to a pool through yearly fee Unplanned Capability to address forced outages in few days drawing on the regional deployment of engine hubs Unplanned coverage in CS Premium fee for tx Customer Mutual commitment with Customer ensures stable operations with controlled OPEX budgets

17 We continue to innovate

18 Product Offerings Nova Family Up to 30 inches Best fuel efficiency +2pts Best MTBM at 35k Best TCO up to 8% advantage Compliant Emissions LM2500 Family Up to 50 inches Up to 10% more power / MTBM extension Up to 25% more power LM... Max Prod. in OFF Frames Family Up to 50 inches Fr Best MTBM at 35+k Fr Fuel flexibility

19 The LM Family Proven Experience LM2500 LM2500+ LM2500+G4 LM2500+G4 Uprate LM6000 PF LM6000 PF+ Power (MW) Efficiency 38% 41% 41% 41% 42% 43% Power (MW) Efficiency LT % LT % LT LM2500 fleet 69+ million hours 37% LM6000 fleet 32+ million hours

20 NovaLT family It s Flexible: Covering #3 LT Models & beyond It s Uniform: Increasing Customer acceptance It s Forward Thinking: Covering current configuration and future upgrades LT5 LT12 Engine Package LT16 Use of Proven Technology Standardized Installation and Maintenance Fleet-wide Experience THE LT MODULAR PLATFORM CONSISTS IN MATRIX OF VARIABLE MODULES

21 NovaLT Innovative Financing Solutions 1 Deferred payment 2 Leasing 3 Operating leasing 4 Fees per Fired Hours Client Fee + fired hours Client GE IFS Client Client Highlights Highlights Highlights Highlights Standard O&G billing milestones with extended payment terms Terms and Conditions: a. O&G Standard T&Cs b. Right to Factor (WCS and 3rd party) c. SBLC or payment security No Capex investment replaced by monthly fees At the end of the leasing: Right to buy equipment Renewal of leasing Not renewal of leasing Terms and Conditions: a. Leasing T&Cs b. Subject to IFS approval Limited Capex investment with additional monthly fees Package sold upfront At the end of the leasing: Right to buy equipment Renewal of leasing Not renewal of leasing Leasing for engine Terms and Conditions: a. O&G Standard T&Cs Part of Capex paid before delivery Remaining part after Delivery (max 3y) SBLC to be issued before delivery to cover payments after delivery Payments after delivery invoiced as monthly fees Terms and Conditions: a. O&G Standard T&Cs b. SBLC for cash after delivery b. Leasing T&Cs All options are subject to GE approval after due diligence process. Cost of Capital have to be considered on top at the starting price

22 Integrated motor driven compressor solution Vincent Megret Unit Director of SKF Magnetic Mechatronics (S2M)

23 Integrated motor-driven compressor Key Features: A single casing for compressor and motor No gearbox. High-speed motor, up to 15 MW No lube oil system. Active Magnetic Bearings No external motor cooling system, process gas No seal gas system Compact package, flexible & reliable operation Minimized maintenance, zero emissions and low noise 34 units sold, 140,000+ running hours and 5,000+ starts

24 Active Magnetic Bearings (AMBs) technology SKF bring unparalleled experience in AMBs heavy rotating equipment installed for Oil & Gas applications 230+ compressors, driven by gas turbines or electric motors, up to 32MW Working with GE since 1987 for the 1 st compressor on AMBs Developed canned solutions for upstream/subsea together with GE Advantages for GE s turbomachinery No contact friction and wear... longer life, minimum maintenance No lubricant and lube oil system... compact skids Higher rotating speed on CC... performance Monitoring capabilities, optimized parameters... digital solutions Collaboration to develop the use of active magnetic bearings within the Oil & Gas sector GE Oil & Gas will use SKF s leading magnetic bearing technologies from front-end engineering to installation, testing and service to customers The partnership also provides the basis for future technology developments, widening the applications of AMBs into other GE turbomachinery, such as steam and gas turbines

25 Eta test Eta max theor. High High efficiency efficiency centrifugal centrifugal pumps The Efficiency Roadmap GE new technology (pat.pend.) 2% 1% 0% -1% -2% -3% -4% -5% Hydro optimization DVS BB1 MSN BB3 Special process Special materials Above max theoretical efficiency by innovative double suction arrangement '10 '11 '12 '13 '14 '15 '16 '17 Double number of blades Lower hydraulic losses Lower disk friction losses

26 Enhanced flow measurement Leak Detection Problem Statement: Pipeline Leak Detection Systems still fail to detect leaks over 100 reported leaks per year in US alone Operators targeting 50% reduction in false alarms while retaining sensitivity Flow meters arguably the most critical instrument for ILD Our Technical Advancement: 4 additional Ultrasonic paths compensate for transient conditions within the pipeline holding accuracy as conditions change The additional paths provide swirl diagnostics that serve as inference for parameters Benefit to you: Transient changes (pumps, batching, etc.) no longer cause false alarms due to steep drops and increases in flow Viscosity and Density from the diagnostics eliminate the need for additional instrumentation and provide more data feeding into the ILD algorithms Traditional 4 path USM design New 8 path USM chord locations

27 Typical ILD System Deployment Diagnostic Suite SPRT Modeling

28