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Servelec Controls is an independent systems integrator, providing missioncritical control and safety systems to oil and gas operators across the world. Servelec Controls provides systems and support services to monitor critical rotating equipment and real-time centre of excellence in Aberdeen and boasts a client list which features the major operators in the UK Continental Shelf and beyond. The client for this case study is an Aberdeen-based oil and gas operator with interests in many fields on the UK Continental Shelf and operates more than 10 offshore installations.


2,800 pieces of equipment monitored


24 days downtime saved on two pieces of equipment


Reduced third-party licensing costs $9m lost revenue avoided on two pieces of equipment


Sharing of information improved

The Brief

As a result of increased scrutiny on asset utilisation and a desire to extend the life of existing infrastructure, our client introduced a dedicated programme to address the overall performance of rotating equipment. The programme improved reliability and integrity as well as minimising production downtime of the 2,800 pieces of major rotating equipment in operation across their assets including turbines, compressors and safety critical equipment.

Prior to Servelec Controls’ solution, much of this equipment was monitored using third-party systems, with each focussed on a single type of equipment, with their own requirements for instrumentation and varying licensing costs. Although the operator had been using OSIsoft’s PI System for management of real-time data and events, information being gathered from a range of rotating equipment was delivered inconsistently, due to the number of monitoring software packages in use.

Business Benefits

The use of a single consistent automated monitoring system in the client’s upstream operations adds value to the process of integrating new or upgraded equipment into the application. A better business case can be produced showing the historical benefits for similar equipment and display the ease by which new equipment can be integrated into an enhanced maintenance management regime. One of the key benefits of the software is that it has improved internal collaboration, particularly between onshore and offshore teams. With all staff using one system, information is easily shared and acted upon by a range of technical and non-technical users.

 

 

 

Servelec Controls’ solution helped the client improve reliability and integrity of rotating equipment through effective monitoring and maintenance. The system was designed to be

expansible and allow the integration of new equipment and processes. As the system was developed and updated by Servelec Controls its reach was easily extended as the needs of the client changed and has since been deployed for other customers.

Servelec Controls’ solution helped the client improve reliability and integrity of rotating equipment through effective monitoring and maintenance. The system was designed to be expansible and allow the integration of new equipment and processes. As the system was developed and updated by Servelec Controls its reach was easily extended as the needs of the client changed and has since been deployed for other customers.

 

The Solution

Working collaboratively with the client Servelec Controls developed an application, which was based on the familiar PI System infrastructure, to monitor critical equipment throughout their upstream operations.

The evolutionary application provides a central monitoring system across the client’s entire network, and presents information in a consistent manner across all assets, promoting ease of use and reducing third-party licensing costs.

Equipment monitored by the application is shown on a standard display providing information on process values and equipment operating points. Summary displays allow non-technical staff to focus on individual assets and interpret key data, with more detailed data readily accessible for those that require it. The application was developed to continuously monitor live values against alarm limits and thresholds, with notifications provided instantaneously via email. Prior to the development of the software by Servelec Controls, this data had to be monitored and analysed manually.

Development of the application has brought real value to the way the client maintains its critical rotating equipment. The system has reduced the lead time on the detection of performance and integrity issues, allowing for swifter action in resolving operational problems. The application’s history functions allow users to make informed proactive decisions and minimise downtime by using historical data to control equipment and prevent production or mechanical issues.

Reducing Downtime

The client has been able to take preventative actions that have avoided or minimised downtime, which is a critical key performance indicator for their business:

  • The application detected a differential pressure that was well beyond the operational limit and alerted the relevant personnel to the situation. Without such an alert, filter damage would have caused an estimated 14 days of downtime with consequent deferment resulting in $6million of lost revenue at a $40/bbl level.
  • Similarly by monitoring the temperature of a high seal oil tank, onshore users were alerted to a reading significantly above the standard temperature. Seal failure could have caused ten days lost production equating to lost revenue of around $3million.

Real-time Critical Rotating equipment Monitoring

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