下载PDF
Saving millions with a predictive asset monitoring and alert system
技术
- 分析与建模 - 预测分析
- 自动化与控制 - 监督控制和数据采集 (SCADA)
- 功能应用 - 计算机化维护管理系统 (CMMS)
- 传感器 - 温度传感器
- 传感器 - 振动传感器
- 传感器 - 电压传感器
适用行业
- 石油和天然气
适用功能
- 维护
用例
- 预测性维护
挑战
挑战在于收集和筛选这些数据，识别表明资产故障可能性很高的模式，识别最紧迫的问题，并为工程师提供正确的信息，并有足够的准备时间让他们采取有效的行动。
“以前，我们只使用了我们收集的运营数据的 10% 到 12%，这是行业平均水平，”Benn 评论道。 “当我们搜索、整理并将正确的信息转发给正确的人时，我们可能响应太晚以避免影响运营，或者不得不在最后一刻更改我们的维护计划，这会降低效率。我们的挑战是主动提供及时、可操作、有效的信息，而不是被动或回顾性评估。”
“我们想要的是一种识别传感器数据模式的方法，这将为我们提供资产故障的早期预警。我们看到了使用分析技术从我们已经拥有的系统和数据中提取更大价值的机会，这将帮助我们避免例如可预防的故障并可能节省数百万美元。
客户
桑托斯
关于客户
Santos Ltd. 是亚太地区领先的石油和天然气生产商之一，服务于澳大利亚和亚洲的家庭、企业和主要行业的能源需求。 Santos 报告的年收入为 40 亿澳元（29 亿美元）。
解决方案
为了创建有效的设备故障警报系统，Santos 采用了预测模型。在 IBM® SPSS® Lab Services 的帮助下开展试点项目，该公司从多个来源提取结构化和非结构化数据，包括： 设备趋势数据库，用于跟踪 SCADA 数据，例如压缩机的运行速度；操作员轮班日志，现场操作员记录其活动的系统；维护资产及其维护历史记录的计算机化维护管理系统；以及资产损失和可用性系统，这是一种用于追踪生产损失来源的会计解决方案。
Steven Benn 说：“我们现在可以使用来自多个来源的信号从所有相关数据流的整体模式匹配和分析中识别问题。我们分析的正是这种整体情况，以便为我们的工程师和现场操作员生成警告和通知。这些警告中的大多数不能来自单一来源或点传感器，否则将无法检测到。”
收集的数据
Temperature, Vibration, Voltage
运营影响
数量效益
相关案例.
Case Study
Taking Oil and Gas Exploration to the Next Level
DownUnder GeoSolutions (DUG) wanted to increase computing performance by 5 to 10 times to improve seismic processing. The solution must build on current architecture software investments without sacrificing existing software and scale computing without scaling IT infrastructure costs.
Case Study
Remote Wellhead Monitoring
Each wellhead was equipped with various sensors and meters that needed to be monitored and controlled from a central HMI, often miles away from the assets in the field. Redundant solar and wind generators were installed at each wellhead to support the electrical needs of the pumpstations, temperature meters, cameras, and cellular modules. In addition to asset management and remote control capabilities, data logging for remote surveillance and alarm notifications was a key demand from the customer. Terra Ferma’s solution needed to be power efficient, reliable, and capable of supporting high-bandwidth data-feeds. They needed a multi-link cellular connection to a central server that sustained reliable and redundant monitoring and control of flow meters, temperature sensors, power supply, and event-logging; including video and image files. This open-standard network needed to interface with the existing SCADA and proprietary network management software.
Case Study
Refinery Saves Over $700,000 with Smart Wireless
One of the largest petroleum refineries in the world is equipped to refine various types of crude oil and manufacture various grades of fuel from motor gasoline to Aviation Turbine Fuel. Due to wear and tear, eight hydrogen valves in each refinery were leaking, and each cost $1800 per ton of hydrogen vented. The plant also had leakage on nearly 30 flare control hydrocarbon valves. The refinery wanted a continuous, online monitoring system that could catch leaks early, minimize hydrogen and hydrocarbon production losses, and improve safety for maintenance.
