Should the number be a variable e. A vertical bar change bar in the margin indicates a change, addition or deletion in the adjacent text for the current revision of that page only.
The change bar is dropped at the next revision of that page. The number of items required by the FAR must be operative. NOTE: To the extent practical, placards should be located adjacent to the control or indicator for the item affected; however, unless otherwise specified, placard wording and location will be determined by the operator.
Alphabetical symbol in Column 4 indicates a proviso condition or limitation that must be complied with for operation with the listed item inoperative. Notes are used to identify applicable material which is intended to assist with compliance, but do not relieve the operator of the responsibility for compliance with all applicable requirements. Notes are not a part of the provisos. Inoperative components of an inoperative system: Inoperative items which are components of a system which is inoperative are usually considered components directly associated with and having no other function than to support that system.
Normally these procedures are accomplished by maintenance personnel; however, other personnel may be qualified and authorized to perform certain functions.
Procedures requiring specialized knowledge or skill, or requiring the use of tools or test equipment should be accomplished by maintenance personnel. The satisfactory accomplishment of all maintenance procedures, regardless of who performs them, is the responsibility of the operator. Appropriate procedures are required to be published as part of the operator's manual or MEL. Normally these procedures are accomplished by the flight crew; however, other personnel may be qualified and authorized to perform certain functions.
The satisfactory accomplishment of all procedures, regardless of who performs them, is the responsibility of the operator. Appropriate procedures are required to be published as a part of the operator's manual or MEL. An acceptable method of securing or deactivating will be established by the operator.
This does not preclude operating under Instrument Flight Rules. Category A. The satellite overview tool can display production flow rate over time. The shutdown incident report tool of the system can provide access to tools selected from the group consisting of administration, shutdown incident report generation, root cause analysis, maintenance strategy, planned maintenance routines, technical changes, report generator, and the like, and any combination thereof.
The compressor envelope tool can display compressor status performance and envelope map showing current operating points on the map. The uptime and availability tool can display uptime and availability of an asset expressed as a percentage over a user selected period.
The loss summary tool is operable to generate a summary of shutdown incident report information with respect to production losses for a selected asset and detail losses attributable to an independent service contractor and deferred production for the asset. Another embodiment of the invention is a method of real time process asset management. The expert system can include logic rules and algorithms for generating the expert alerts. Updating the failure logic rules can include capturing knowledge from failure analysis.
One or more of the expert alerts can include remote user notification via a telecommunication device. One or more of the expert alerts can include notification via an access portal graphical user interface. The transmission of the corrective action request to the work management system can include generating a request to resolve one or more of the expert alerts via the access portal. The expert system can include calculation instructions and logic algorithms for generating the expert reports.
The updated data in the expert system can include engineering analysis, production loss reporting, simulation model output, and the like, or a combination thereof.
The method can include delivery of the expert reports to a remote user via a telecommunication device. The method can also include display of one or more of the expert reports in a line of sight format via an access portal graphical user interface. The method can additionally include sending a request to resolve production loss via the access portal to a workflow engine for root cause analysis, issue resolution, and the like, or a combination thereof, to generate the corrective action request to the work management system.
The method can also include exchanging simulation data between the expert system and a process simulation model. Additionally, the method can include adjusting processing parameters between the process simulation model and process engineering model data. The method can also include adjusting optimization parameters between the expert system and the process engineering model data.
One or more of the expert reports can include production variance data. The production variance data can be transmitted to a remote user via a telecommunication device. The one or more of the expert reports can include optimization opportunities.
The optimization opportunities can be transmitted to a user via an access portal graphical user interface. The transmission of the optimization action request to the work management system can include generating a request to adjust operating parameters via the access portal.
A further embodiment is a method of real time performance management, including the steps of: a interfacing an enterprise system database with one or more functional system databases and a user interface; b exchanging data between the enterprise system database and an expert system for calculating performance metrics of the enterprise functions; c exchanging data between the expert system and the one or more functional databases; d building a functional group performance model for use by the expert system; e sending status reports from the expert system to a user; f displaying a trend reports via a line of sight access portal graphical user interface; g transmitting a request to resolve function group performance issues via the access portal to a workflow engine for the respective functional group; h sending a corrective action request from the workflow engine to a work management system; and i repeating a through h on a real time basis.
The expert system can include logic rules and algorithms for generating the expert reports. The logic rules updating step can include capturing knowledge from functional group performance. One or more of the expert reports can include remote user notification via a telecommunication device, and additionally or alternately notification via an access portal graphical user interface.
The access portal can include a navigation table comprising a first dimension of grouping attributes comprising planning, actions, and results, and a second dimension of grouping attributes comprising people, equipment, and cost, for the purpose of grouping access to tools associated with the support module.
The planning group can provide access to maintenance tactics and strategy tools, the actions group to defect elimination and loss prevention tools, and the results group to facilities, maintenance, and production performance tools. The navigation table can include access to an operations knowledge capture tool, which can include a database of information collated on process equipment items and respective recorded system defects, containing engineering and operational experiences of causes and effects of the system defects, and the like.
The recorded systems defect data can include symptoms, severity, consequence, detection mechanism, and the like, or any combination thereof, and can additionally or alternately include data selected from the group consisting of defect occurrence frequency, logic rule frequency, rules, recommended remedial actions, report recipient, miscellaneous comments, and any combination thereof. The method can further include using an updating tool associated with the operations knowledge capture tool to populate the enterprise database with data selected from the group consisting of shutdown incident report data, vendor data, expert knowledge, and the like, and combinations thereof.
The navigation table in the method can also include access to a shutdown incident report register tool. The shutdown incident report register tool can include access to information from shutdown incident reports selected from the group consisting of report number, time back, functional responsibility, date raised, product lost, fault found, loss category, cost, corrective action, sent to, cause category, asset focal point, source location, independent service contractor loss, outstanding action, maintenance work request, time down, responsible asset, review process, explanation of problem, explanation of event, close out, and the like, and any combination thereof.
The shutdown incident report register tool can provide access to tools selected from the group consisting of administration, shutdown incident report generation, root cause analysis, maintenance strategy, planned maintenance routines, technical changes, report generator, and the like, and any combination thereof.
The method can also include the step of defining shutdown incident report templates via the administration tool. The method can include operating the shutdown incident report generation tool to generate a shutdown incident report including data selected from the group consisting of person generating, person sent, loss category, independent service contractor loss, cause category, responsible asset, explanation of event, source location, time down, and the like, and any combination thereof.
The method can include operating the root cause analysis tool to generate a shutdown incident report including data selected from the group consisting of date raised, focal person, execute root-cause-analysis-preventive-corrective-maintenance RCA-PCM date, recommended corrective action, actions completion date, cost benefit analysis, approval or rejection date, planned execution details, implementation date, close out date, and any combination thereof.
The method can further include operating the maintenance strategy tool to generate a shutdown incident report including data selected from the group consisting of date raised, execute root cause analysis and preventative care maintenance date, strategy number, action completed date, cost benefit analysis, execution planned date, execution implemented date, close out date, and the like, and any combination thereof.
The method can include operating the maintenance routines tool to generate a shutdown incident report including data from the group consisting of date raised, execute root cause analysis and preventative care maintenance date, strategy number, action completed date, cost benefit analysis, execution planned date, execution implemented date, close out date, and the like, and any combination thereof.
The method can also include operating the technical changes tool to generate a shutdown incident report including data from the group consisting of date raised, execute root cause analysis and preventative care maintenance date, strategy number, action completed date, cost benefit analysis, execution planned date, execution implemented date, close out date, and the like, and any combination thereof. The method can also include operating the report generation tool to generate a report including data from the group consisting of total asset shutdown performance, downtime by cause categories for source locations date range, downtime by source locations date range, downtime by loss category for responsible asset date range, production loss by functional responsibility date range, recurring events date range, shutdown incident report date range, issues report date range, and the like, and any combination thereof.
The people grouping can include tools selected from the group consisting of preventative maintenance workload, history and plan, maintenance supply and demand, critical actions register, idea database, action log, preventative maintenance compliance, ratio of preventative maintenance to corrective maintenance work, productivity, corrective performance, man hours expended, total maintenance backlog, completion of defect elimination action, and the like and any combination thereof.
The method can also include accessing, via a home page of the access portal, tools selected from the group of asset performance metrics, leadership team, maintenance, supply chain management, planning, well operation, human resources, emergency response, field team, facilities, engineering and construction, and the like, and any combination thereof.
The method can include displaying a geographical representation of the process on the access portal. The access portal can include an asset performance tool. The method can also include providing real time asset statistical data selected from the group of production rate, deferment, uptime, availability, and the like, and any combination thereof, via the asset performance tool.
The method can also include operating the asset performance tool to access tools selected from the group of infrastructure overview, choke model, status, traffic light, production performance, expert, satellite overview, shutdown incident report, compressor envelope, uptime and availability, loss summary, and the like, and any combination thereof.
The method can include generating defect alarms and recommended actions via the expert tool. The shutdown incident report tool can provide access to tools selected from the group consisting of administration, shutdown incident report generation, root cause analysis, maintenance strategy, planned maintenance routines, technical changes, report generator, and the like, and any combination thereof.
The real time operations support provided in one embodiment comprises a portal-based decision support process, knowledge management and asset performance monitoring system for the effective operations and maintenance of an asset.
The system facilitates a line of sight through an organization, from the asset performance goals to the actions that deliver them at various levels and across various functions within the organization. It is desirable that the levels and functions are substantially or essentially comprehensive. The system provides for the analysis and display of performance metrics and supporting actions by personnel with the appropriate access profile, thereby providing the production process for an operation to be readily viewed and managed.
The asset has sources of data that are used to effectively describe the performance of the asset in terms of cost, throughput, uptime, energy efficiency, product quality, operational conditions and the like. A non-limiting list of sources of data can include control systems, operational parameter readings manual, electronic, pneumatic, etc. In one embodiment the present invention provides real time operations support analysis algorithms and data extraction processes that leverage the reservoir of data that exists in production facility supervisory control systems and client enterprise management systems.
These applications can extract key performance information, including production loss or deferment, and loss causation information, as well as equipment uptime performance. The extraction and presentation of these performance metrics facilitates improved decision-making within operations and maintenance support teams.
Real time asset performance information gathered from control systems and other information sources can be brought together in the line of sight management system, which can be designed to be the operations and maintenance support control panel or dashboard.
The access portal technology enables a real time access medium for production and maintenance management information. The benefits that the present invention provides to a support organization include the capability for focusing support team efforts on value-based decisions and the measurement of their alignment with asset goals.
Asset performance can be viewed from any authorized workstation with access, thereby enabling subject matter experts to support operations, regardless of their physical location. The present invention can provide significant value to an operation, especially with the engagement of local operations and maintenance teams associated with the asset. Embodiments of the present invention can provide, in some cases, as much as 30 percent in cost reductions through reduced operating and maintenance staff needs as well as reduced equipment repair expenses.
Uptime improvements of, for example, 3 to 8 percent can be achieved, depending on the reliability of the operation. Significant value can be realized by each function in the support organization that can observe and measure their performance on a real time basis.
The alignment and clear line of sight through an organization provided by the invention can deliver a reduction in the level of resources required to provide the support function and at the same time can improve the work product. A fully aligned organization is one that applies the right resource, at the right time to the point of need for an operation, and has high efficiency. The present invention can provide the distinct benefits of showing the relationships between cross-functions that support an asset and building a clear picture of how the organization can align actions to goals.
The line of sight model enables each support function group to measure its performance to suit the overall business goals and introduces significant rigor to the process.
The present invention provides the ability to significantly improve the performance of an operating facility by having access to performance information that drives effective facility improvements.
The system can push information to the user, as opposed to an information pull by the user, so that time is not wasted searching for the information needed for decisions. Effective asset optimization can be facilitated from a presentation format that is not traditionally available. With the present invention, the capture of knowledge of asset operation from operating and maintenance staff can facilitate the retention of enterprise operating knowledge. Another value is the matching of an understanding of the failure potential with the delivery of mitigation measures to prevent recurrences.
This is particularly the case in maintenance and operating related knowledge that might be held in memory by enterprise or operations personnel in the prior, art methodologies, but is not more permanently captured for future use. The present invention can provide more consistent operations through the use of expert systems that employ captured knowledge and technical experts embedded in control systems.
By capturing knowledge from mature operators and facility personnel and then combining it with process technical knowledge, the present invention facilitates retention of operational and asset process knowledge and consistent application over the life of the asset. The present invention provides defect-elimination processes and tools to reduce corrective maintenance work activity and associated costs.
The preventative maintenance decisions facilitated by the present invention can focus both technical and operating resources to reduce production losses and deferments. These can be reflected in the revenues from improved production volumes. Cost improvements can also be realized through improved equipment life and lower maintenance needs. Use of real time loss and cost information can often justify asset improvements more effectively and enhance performance.
The present invention can optimize maintenance activity for proactive and planned maintenance. The expert systems provide intelligence on equipment and system condition to generate maintenance activity by condition, in addition to any strictly calendar-based maintenance activity.
The use of condition-based mechanical integrity analysis can reduce equipment inspection costs, equipment failure incidents, and the associated business and personnel risks.
A significant reservoir of data exists for operating assets and facilities across industries including for example, oil and gas, petrochemical and refining, power generation and utilities, pulp and paper, commercial and specialty chemicals, and the like.
Typical sources of data that are available within an operation and the potential use of that data information delivery according to an embodiment of the invention are shown in FIG. Data information comes in various types with different values and applications for each type of data. The needs necessary to make each decision regarding a piece of data also vary. Real time operations also vary depending upon the type of data and its value and application.
The basic elements and framework for an embodiment of the system architecture of the invention are outlined in FIG. The main elements for delivering a solution for an abnormal operating event, e. This gives an overview of the main elements at a very high level.
Implementation of each element can require several methods and software tools depending on the particular systems an operation uses to manage various aspects of the asset or enterprise. However, the information necessary to manage an event through to a solution can be made available through access portal technology for functional work groups that support and manage the particular asset.
The access portal may also be done as a hardware implementation or by other access means. Information about an asset can exist in multiple sources and systems, including process control systems, enterprise management systems, computerized maintenance management systems CMMS , technical and engineering document management systems, vendor data including both procurement and technical vendor data, equipment monitoring systems, logistics tracking systems, individual staff applications, and so on.
This information can be relative to timeframes that are very short to time frames of a year or more in duration. Illustrative examples are: less than a second for some online vibration monitoring equipment; months for engine oil analysis data, one year for infrared surveys of electrical systems; and 5 years or more for internal inspection of a vessel during a facility maintenance turnaround. In the prior art, the information in these disparate sources are not brought into one location and presented to the organization in a manner that shows the overall picture and cross-functional relationships, and as such the prior art methodology can create silos of inefficiency in an organization that put roadblocks in the path of improving organizational performance and understanding of the asset management processes.
According to an embodiment of the present invention, the real time support process and system facilitates the coordination and alignment of cross-functional support, such as through web technology, and delivers a consistent way of performing asset management processes and measuring their effectiveness on a real time scale. One such process, that is an important part of an operation, is the maintenance process known as defect elimination, which addresses how the maintenance and technical groups systematically eliminate equipment problems in a process plant or manufacturing asset.
The purpose of defect elimination is to introduce and create sustainable reliability of equipment and deliver the maximum product and process uptime in the manufacturing asset to ensure maximum revenue.
This is simply an example of one asset management process in an operation within the maintenance function of the organization, provided for the purpose of illustration and not intended to limit the scope of the invention to other asset management functions.
It illustrates the initial planning and strategic definition that can be used to successfully conduct reliability performance improvements. By taking information from a field or plant and transforming that information into meaningful charts and graphs, defect elimination teams have a better understanding of what problems have occurred, root cause failure analysis reviews can be performed, control system optimization procedures audits can be performed, and the design out of failure can be performed.
In the prior art, most of these steps are manual. In contrast, the real time operations support of the present invention can deliver consistent performance reporting in the decision process, extracted on a real time basis from multiple data sources. The present invention provides the information that is required to make the decisions in such a way so as to shorten the time between the abnormal event and the solution delivery.
The present invention can also facilitate the uniform delivery of the right amount of information provided across several different operations to make consistent, quality decisions and analysis of the abnormal event. The schematic of FIG. These priorities can determine the relative impact that the components and systems have on delivery of a product and are used to focus the elimination of equipment defects to impact production.
The process of analyzing data to determine areas of focus can now be performed in real time and the results presented for action. Traditionally, the analysis of operational data to deliver uptime and loss causation information is a manual process, however, real time operations support in this embodiment of the invention provides the analysis from the appropriate data sources on a real time basis.
It also allows the standardization of the analysis process to give a consistent approach over several operations and a basis for benchmarking equipment and system performance. Certain operational decisions fall into broad and generalized timeframes depending on the nature of the decision and the particular function the decision supports. Relevant timeframes can be less than one second in length for certain aspects of an operation, such as for example, the rotational speed rpm of an operating motor or turbine.
Timeframes of hours, days, or months can be relevant for other aspects of an operation, for example weekly spot measurements or monthly corrosion monitoring. Timeframes of up to a year or more can be relevant for inspections that require entering a piece of equipment, which might only be possible during a complete facility shutdown. In the present invention, production-related decisions can be made on a real time basis.
True real time decision-making in producing operations are typically associated with production control related decisions. These can be made either by the supervisory process control system or by operators that use the information presented by the control systems.
The decisions on a level over and above regulatory and automated control can be determined by the operator and to a large extent are dependent upon operator competence and plant process stability. Decisions can be made ranging from seconds to as much as 24 hours or more, in response to a process parameter excursion, or to an abnormal situation when a process upset occurs. The focus of the present real time operations support in this context is to improve the quality and integrity of production decisions by the use of so-called machine experts or expert systems.
The use of expert system technology is well known in the art and has been applied to the process industries, as well as more diverse applications in, for example, the medical sector.
However, one embodiment of the present invention provides a knowledge capture process that engages technical support and maintenance staff, as well as operating staff. This process enables the structured capture of process facility, systems and equipment abnormal trends and potential failure mechanisms for use in expert systems that make use of process control systems. This process also allows for a user to quickly and efficiently search for data regarding a particular asset.
The display is made up of three main components: an overview, symptoms of defect, and other or miscellaneous information. The overview component shows which system is involved, who the manufacturer of the asset is, the work breakdown structure or type of asset , the objective of the asset, and the cause of a recorded defect.
The symptoms of defect component shows the symptom the asset is presenting, the severity of the defect, the consequence of the defect, and the detection mechanism utilized to find the defect.
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