Total EP counts on zero unanticipated failures with SmartSignal-powered monitoring center

Total EP is consistently ranked amongst the top 10 integrated operators globally. The company employs more than 100,000 workers and operates in more than 130 countries producing 3 million barrel of oil equivalent (BOE) per day. It is also the second largest liquified natural gas (LNG) supplier, with major investments in low carbon electricity production through dams, solar and wind turbines.

Matias Palacios, a Rotating Equipment Engineer at Total EP, champions the company's mission. “Our commitment to safe, clean, accessible power is a responsibility we take very seriously to support our ambition to become the responsible energy major."

How monitoring gaps and missed leaks led to costly production shutdowns

In 2009, a fire broke out on two compressors on a remote oil production platform in Africa owned by Total EP, one of the world’s top 10 integrated operators. The source was a small leak that had continually increased until the centrifugal compressors failed, and the pressurized gas was released into the lube oil tank of a gas turbine. Then, the mixture of gas and oil made its way to a 400-degree gas turbine vent and ignited a fire. A week later, on unit two of this platform the same event reoccurred. While no one was hurt, the fire forced a six-month shut down of the platform that had been producing 100,000 barrels of oil per day. Had this undetected small leak been caught earlier, it could have easily been fixed.

Unfortunately, these types of failures were not isolated to that plant. Total operates in more than 130 countries producing 3 million barrel of oil equivalent (BOE) per day. It is also the second largest liquified natural gas (LNG) supplier, with major investments in low carbon electricity production through dams, solar and wind turbines. Its operations in desert areas were particularly vulnerable as equipment was exposed to sand. Although vibration levels were being monitored, they were staying within operating parameters and with no way to visually inspect the equipment, damage was not detected until it was severe.

From 2006 to 2010 Total had several gas turbine break downs and compressor failures. Analysis of the incidents revealed that 50% of the failures could have been avoided had monitoring been in place. Not all failures cause the impact of the 2009 compressor breakdown, but Total could see a significant opportunity to take a more proactive approach to identify these failures early.

SmartSignal enables the shift from reactive to preventive maintenance – and zero surprises

To proactively identify equipment degradation and avoid these failures, Total set out to establish a remote monitoring center with access to equipment data coming from critical assets across its global exploration and production fleet. In 2013, the Remote Assistance, Intervention and Diagnosis Center (RAID) was launched with GE Digital’s SmartSignal software to support the center’s monitoring activities. As part of the Asset Performance Management (APM) Reliability solution, SmartSignal provides early and actionable warnings of impending equipment and process problems – moving the organization from reactive to proactive maintenance operations.

“We knew the added insight would not only give us greater confidence, but also would save us millions in lost production,” Palacios explains.

When Total first rolled out the RAID system in 2013, four areas were identified as critical to production:

• Power generation
• Gas compression
• Water injection
• Crude oil export

The monitoring operation across these four areas is extensive. 30,000 sensors monitor 260 shaft lines and 540 pieces of equipment. Data is sampled every 10 minutes to limit the burden on data storage without impacting analysis and effectiveness. When SmartSignal identifies a potential deviation, it is flagged directly to the affiliate where it is occurring, along with recommended actions.

When Total first rolled out the RAID system in 2013, four areas were identified as critical to production:

• Power generation
• Gas compression
• Water injection
• Crude oil export

The monitoring operation across these four areas is extensive. 30,000 sensors monitor 260 shaft lines and 540 pieces of equipment. Data is sampled every 10 minutes to limit the burden on data storage without impacting analysis and effectiveness. When SmartSignal identifies a potential deviation, it is flagged directly to the affiliate where it is occurring, along with recommended actions.

Early warnings, early action stop failures before they happen

“Generally, we operate the same kind of equipment from the same manufacturer in very different conditions across affiliates. Applying the same maintenance schedule across locations was leading to failures. Now, we can isolate every potential issue to determine whether it is a design issue or an operating one. This has been essential to improving operations globally,” said Palacios.

As part of a preventive maintenance program, SmartSignal helped:

• Extend meantime between maintenance actions while reducing equipment failures
• Eliminate gas turbine and centrifugal compression failures in monitored fleet
• Hundreds of maintenance actions have been recommended and acted upon eliminating millions of dollars in anticipated down time costs

Operational objectives and benefits include:

• Reduce flaring
• Optimize fuel consumption
• Reinject produced gas & produced water

Since the inception of the RAID center supported by SmartSignal software, Total's ability to proactively anticipate problems has resulted in zero breakdowns across all monitored assets.