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Condition and Performance Monitoring of Emergency Shutdown Systems:

Data Visualization and Analysis for Decision Support

Chapter · August 2020

DOI: 10.1007/978-3-030-48021-9_42

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Condition and performance monitoring of
emergency shutdown systems: Data
visualization and analysis for Decision
support
Pengyu Zhu1, Jayantha P. Liyanage2, Simon Jeeves3

Abstract The critical role of emergency shutdown (ESD) systems is widely

acknowledged in the oil and gas industry. Monitoring the condition and
performance of ESD systems is known to have potential benefits in further
improving cost-effective production, while ensuring safety availability. This paper
takes a special perspective on data visualization and analysis for decision support
regarding ESD systems. The paper identifies the needs and expectations of core
stakeholders and explores how to improve the user interface of a condition and
performance monitoring system. The proposed solution has a focus on obtaining the
most critical data and information in a visualized and integrated interface and on
accessing automatic trending and failure analyses to assist decision-making.

1 Introduction
Emergency shutdown (ESD) systems are widely used in the process industry,
which involves large volumes of flow during operations. ESD systems are mainly
designed to shut down production flow in the case of emergencies and to limit the
escalation of hazardous events before and when they occur (NORSOK, 2008). A
failure of ESD systems on demand can be a great threat to production safety and
availability.
In the oil & gas (O&G) industry on the Norwegian continental shelf (NCS), ESD
systems have been managed, using corrective maintenance strategies in more
traditional terms. However, several critical ESD systems, such as downhole safety
valve systems (DHSV), have recorded an unsatisfactory average failure frequency
over the last 15 years (Petroleum Safety Authority Norway, 2017). The application

1Pengyu Zhu ()

University of Stavanger, Norway
e-mail: pengyu.zhu@uis.no
2Jayantha P. Liyanage
University of Stavanger, Norway
e-mail:j.p.liyanage@uis.no
3Simon Jeeves
MRC Global, Norway
e-mail:simon.jeeves@mrcglobal.com
2 P. Zhu, J.P. Liyanage, S. Jeeves- Condition and performance monitoring of ESD systems

of condition and performance monitoring systems to ESD systems has been

discussed as being helpful in early failure/degradation detection, automatic data
collection, increased safety failure fraction, decreased probability of failure on
demand (PFD), and so on (Greenlees & Hale, 2012; Juvik, Hermansen, Carr, &
Hale, 2002; Lundteigen & Rausand, 2007; Zhu, Liyanage, & Jeeves, 2019).
However, in general, there has not been a major focus on the advanced use of
condition and performance monitoring applications on ESD systems, as well as on
other asset-critical on-demand systems, due to specific operational practices. There
is a need to raise the awareness, among both service providers and asset owners, of
the exploration of new practices, especially focusing on collecting and analyzing
relevant data and improving decision support regarding ESD systems.

2 Research methodology
This paper is a part of a research study, conducted in collaboration with the oil
& gas industry, in relation to operation and maintenance decision support of ESD
systems. Data were collected based on 21 surveys conducted with both current and
potential users of the system, technical service providers, researchers, and safety
authorities during a period of over two years. Data and materials were also collected
through interviews with experts, who had extensive experience and knowledge of
the studied system. A specific condition monitoring application technology for ESD
systems, called ValveWatchTM , provided the basis for this paper to further explore
the potential use of a visualization and analytical interface to improve the current
practice.

3 ValveWatchTM technology to monitor condition and

performance of ESD systems
ValveWatchTM is an automated online condition and performance monitoring
system for critical valve systems, including ESD systems (Valvewatch, 2017). The
original development of the monitoring system dated back to 1997, as a response to
the Piper Alpha disaster (Juvik et al., 2002). The ValveWatchTM system was the
first of its kind for monitoring critical valve systems in the O&G industry. The
system collects, visualizes, and analyzes real-time condition data from multiple
sources, to support decision-making. It allows users from different disciplines and
geographical locations to collaborate seamlessly and simultaneously.

ESD tagNo. ESD tagNo. ESD tagNo.

ESD tagNo. ESD tagNo. ESD tagNo.

ESD tagNo. ESD tagNo. ESD tagNo.

Good Degraded
Failure
condition condition

Figure 1 ValveWatchTM interface for monitoring ESD systems

P. Zhu, J.P. Liyanage, S. Jeeves - Condition and performance monitoring of ESD systems 3

When entering the ValveWatchTM interface, users are shown a visualized real-
time condition and performance overview of all monitored ESD systems, as
depicted in Figure 1. The conditions of systems are clearly marked and presented
with different colors, representing the health conditions of systems, giving users an
insight into the overall picture.
A data directory page is also provided, if users want to look into details of a
specific system’s condition. Graph previews of real-time sensor signature curves,
such as stem torque curves and actuator pressure readings, are plotted and displayed
for diagnosis and prognosis purposes, as shown in Figure 2. In practice, pattern
recognition analysis and trending analysis are used to carry out diagnostic and
prognostic analyses (Hale, 2003; Juvik et al., 2002; Zhu et al., 2019). The
implementation of such analyses, however, largely depends on experts’ ability to
interpret the data. Extensive knowledge and experience of the mechanical and
electronic principles of the ESD system, data analysis, and operation and
maintenance basics of the system are greatly needed for such tasks.

Figure 2 Sensor readings during ESD system operation

4 Identification of users’ needs of ValveWatchTM

In practice, ValveWatchTM users were divided into three main groups: offshore
users (asset owner), onshore users (asset owner), and onshore users (monitoring
service provider). It is important that each group of users has access to the right data
and information, in order to make informed decisions. In addition to condition data,
equipment data, operation & maintenance data, failure history, reliability data
(failure rate), and failure mechanism data are also critical contextual data for all
users, regarding ESD systems (ISO 14224, 2016; OREDA, 2015). Different users’
roles, responsibilities, and requirements for data & information were identified,
based on a series of surveys and discussions, as shown in Table 1.
4 P. Zhu, J.P. Liyanage, S. Jeeves- Condition and performance monitoring of ESD systems
Table 1 Roles, responsibilities and data needs of user groups

Onshore user Onshore user Offshore user

Users
(service provider) (asset owner) (asset owner)
-Registration of -Registration of
-Collection & analysis
maintenance maintenance
of condition data
notification notification
Role -On-site service
-Maintenance -Implementation of
-Periodic valve
planning and inspection, repair and
performance report
optimization replacement
-Failures are reported -Prioritization of -Failures are reported
upon detection work orders upon inspection
Responsibility
-Identification of -Ensure safety level -Work orders are
failure causes is fulfilled carried out
-Equipment data -Equipment data
-Equipment data
-Condition data -Condition data
-Operation &
-Failure data -O&M data
maintenance (O&M)
Data needs -Reliability data -Failure data
data
-Failure mechanism -Reliability data
-Failure data
-Key performance -Failure mechanism
-System KPIs
indicators (KPI) -System KPIs

It was noted that, as a common practice, data were stored on different

information management platforms and communicated in inconsistent forms. In
addition to this, users often found it time-consuming and challenging to perform
holistic analysis of available data. There was a need for an improved, insightful data
management and visualization solution, which can provide the relevant basis for in-
depth analyses, to support informed decision-making. Thus, in the next section, a
suitable data visualization and analysis solution is proposed, to enhance the decision
support capability.

5 Developing a data visualization and analysis solution

Developing an effective data visualization and analysis solution for ValveWatch
was a key deliverable of the research study. With the extended availability of
contextual data from online condition monitoring programs, this study explored a
number of technical aspects for improved decision support regarding ESD systems.
5.1 Data modeling
One major purpose of having online condition and performance monitoring
systems is to make early detection of failure/degradations possible and practical,
and to eventually improve the safety levels of ESD systems. The demands of
different users for data, as summarized in Section 4, need to be fulfilled. The study
investigated the need for such a logical data model to holistically describe the scope
and data interfaces between the technical system, ValveWatchTM , SAP or
computational maintenance management systems (CMMS), and users. A brief
logical data model, built using crow’s foot notation, is shown in Figure 3.
 SAP/ CMMS/etc.
PK tagNumber report to
report to report to
KPIs,alarms
report to report to
failure history
report to report to

valve actuator solenoid filterRegulator utilitySupply logicSolver inputSensor

PK itemID PK itemID PK itemID PK itemID PK itemID PK itemID PK itemID

accessed by parts parts parts parts parts parts parts

failureModes failureModes failureModes failureModes failureModes failureModes failureModes

failureHistory failureHistory failureHistory failureHistory failureHistory failureHistory failureHistory

reliability reliability reliability reliability reliability reliability reliability

data feedback
monitored by monitored by
monitored by monitored by monitored by report to
monitored by monitored by

monitored by
monitored by monitored by
monitored by

monitored by
monitored by

actuator pressure strain gauge position transmitter stem leak sensor dynamic leak sensor acoustic leak sensor visual inspection
sensor
PK senserID PK senserID PK senserID PK senserID PK senserID PK senserID
PK senserID
stemTorque valveTravel externalLeakage differentialPressure turbulanceFlow deviations
actuatorPressure

visualized visualized
visualized
visualized visualized
visualized visualized

Valvewatch interface
PK tagNumber/systemID
Users
KPIs & alarms
PK userID
failureMechanism
P. Zhu, J.P. Liyanage, S. Jeeves - Condition and performance monitoring of ESD systems

accessed by

Figure 3 Data model of online monitoring system using crow’s foot notation
Roles
parameterTrending
Responsibilities
failureRate
5
6 P. Zhu, J.P. Liyanage, S. Jeeves- Condition and performance monitoring of ESD systems

5.2 A holistic overview of ESD systems in the operating phase

In practice, the results of most analyses are communicated through technical
reports or offshore visits. The level of understanding of the diagnostic and
prognostic analyses and the complexities of analyses’ reports can easily make it
difficult for them to be integrated and described in the current interface. Based on
this study, an intuitive interface is suggested, as shown in Figure 4, that embeds
concise but holistic data & information and provides a practical visualization and
analysis basis for decision support.
In practice, various ESD systems are managed, tested and evaluated in groups,
such as riser ESD system and downhole safety valve system (DHSV). It is natural
for all monitored ESD systems to also be displayed in groups in the overview
interface. Hauge and Lundteigen (2008) explained the need for and importance of
updating the PFD and safety integrity level (SIL) of different systems in the
operating phase and explained how function test intervals can be determined, based
on failure data and operation experiences. In the new interface, these key
maintenance parameters are displayed when users click on a certain group of ESD
systems. The quantitative values are calculated using embedded analytic engines,
based on failure data that are automatically extracted from SAP or CMMS. Failure
histories related to a specific group of ESD systems are displayed by activating the
‘Failure history’ function. Users can also click on a specific ESD system node to
call up the system synopsis window, which shows brief information and the
condition of the system, as depicted in Figure 4Feil! Fant ikke referansekilden..
Some advanced analyses, such as safety factor trending and failure analysis, can be
accessed by pressing the respective button shown in the window.

Figure 4 Enhanced overview of ESD system groups

P. Zhu, J.P. Liyanage, S. Jeeves - Condition and performance monitoring of ESD systems 7

5.3 Trending of system performance

System performance is measured continuously with ValveWatchTM . However,
for most users, data collected at key valve positions, such as valve break-to-close
point, are of the greatest interest. The sampling process is achieved with the use of
a position transmitter. The reduction in data that need to be processed and analyzed
is helpful in reducing both workload and competence requirements. There are
several ways to visualize the data sets, to reveal system condition and performance.
The monitoring of safety factors or function margins of actuated valve systems
has been applied in the nuclear industry since the 1980s (U.S. Nuclear Regulatory
Commission, 1989; Hale, 2003). On the NCS, ValveWatchTM introduced the
concept of measuring safety factor degradations regarding critical valve systems in
the O&G industry (Juvik et al., 2002). For an ESD system, operability is a major
concern. The ratio of actuator force to friction is thus defined as a key safety factor.
Readers should bear in mind that this safety factor needs to be higher than 1 in order
to operate an ESD valve. Instead of plotting detailed sensor readings, as shown in
Figure 2, the trending of safety factors at the most critical valve positions gives a
clear picture of system operability and performance and is suggested, as depicted in
Figure 5.
7.0
6.0
5.0
4.0 test 1
Safety factor

3.0
test 2
2.0
1.0
Break Run to End to Break Run to End to
to open open open to close close close
Valve position
Figure 5 Trending of safety factor of ESD system, an example
A decrease in a safety factor, if still above 1, reveals a developing failure of the
system. It raises the need for further investigation, when the degree of degradation
becomes unacceptable, based on predefined criteria. However, not all degradations
can be revealed by simply trending the safety factor. Increased friction, due, for
example, to debris, may be overcome by an oversized actuator. Detailed
performance indicators are sometimes needed to reveal root causes.
16000
6000
14000
5000
12000
Actuator force (Nm)

10000 4000
Friction (Nm)

8000 3000
6000
2000
4000
2000 1000

0 0
Break to Run to End to Break to Run to End to Break to Run to End to Break to Run to End to
open open open close close close open open open close close close
Valve position Valve position
Actuator force-test 1 Actuator force-test 2 Friction-test 1 Friction-test 2

Figure 6 Trending of maintenance KPIs of an ESD system, an example

8 P. Zhu, J.P. Liyanage, S. Jeeves- Condition and performance monitoring of ESD systems

The trending of key performance indicators (KPI) of the ESD systems is

suggested, as it provides extra insight into the detection and analysis of early
failures/degradations. In traditional terms, KPIs regarding ESD systems were often
defined to measure the overall system performance, such as valve travel time and
internal valve leakage rate at closed position (Petroleum Safety Authority Norway
et al., 2016; Norwegian Oil & Gas Association, 2017). With the increased
detectability, more detailed KPIs can be and should be defined, such as breakout
torque to move a valve. Historical measurements of these KPIs are trended, and
degradations can be revealed that are otherwise hidden by simply trending the safety
factor. At the ‘break-to-close’ valve position, for example, the safety factor of the
system remains stable in two tests, according to Figure 5, but increases in friction
and actuator force are revealed by trending maintenance KPIs, as shown in Figure
6. The monitoring and trending of safety factors and KPIs of ESD systems is a major
step forward to predictive maintenance.
5.4 Embedding failure analysis ability
Failure analyses are normally carried out by dedicated diagnosis experts. They
pick out slight variations on sensor signature curves that have been caused by
different failure mechanisms. Various tools such as fault tree analysis (FTA) and
failure modes and effect analysis (FMEA) are also used to assist analyses. The
authors believe that such a process can be largely captured and modeled into a
digital interface. The key is to establish the links between sensor detectability and
failure mechanism. The detection of early degradations/failures of ESD systems has
been explained and discussed from a failure progression perspective (Hale, 2003;
Juvik et al., 2002; Zhu et al., 2019). A typical mapping approach is illustrated in
Figure 7.

PLC I/O card

Limit switch
Actuator pressure sensor
Position transmitter
ValveWatch
Solenoid current signature
monitoring system
Strain gauge
Dynamic leak sensor
Acoustic leak sensor
Dynamic leak sensor stem

Figure 7 Inter-relationships between sensor readings and failure logic

Expert judgements are valuable during failure analyses, but the authors aim to
introduce an approach that allows anyone to use the system in an intuitive way.
Based on mapping results, an elimination process is followed so that users can cross
off impossible failure causes and consequences and identify the mostly likely
failures, based on reliability data and failure logic, as shown in Figure 8, where
human-related failures are marked with ‘(H)’.
P. Zhu, J.P. Liyanage, S. Jeeves - Condition and performance monitoring of ESD systems 9

The approach aims to find a balance between uncertainty and efficiency. In this
case, uncertainty refers to the identification of the exact failure cause. The suggested
approach provides an extended list instead of a certain failure cause. The list is
recommended according to the failure propagation logic and prioritized based on
the likelihood of occurrence, which is measured by continuously updated failure
rate λ, with failure data from SAP/CMMS systems. The list can be used as a
checklist for the maintenance team. The process provides users with a structured
guide to localize failure and identify failure causes. During the process, a ‘real’
reliability database, based on the corporation’s own practices, will also be
established in the long term, which will improve the precision of prediction, from a
statistical perspective.

Triggering event Failed component Failure modes Failure root causes

Excessive packing (H)

λ Field instrument Actuator load too high Pressure lock in cavity

λ Valve Actuator mechanical failure Stem misalignment (H)
λ Actuator Insufficient actuator capacity Unknown cause
Fail to open/close valve λ Low pressure margin
Solenoid
(FTO/ FTC)
External leakage
λ PLC
Internal leakage
λ Utility medium supply
λ
Torque

Common cause failure

Actuator force
Friction

Valve travel

Figure 8 Assistance for failure analysis

6 Conclusion
Current practices related to condition and performance monitoring of ESD
systems have been developed, based on operational experience in the O&G industry
and nuclear industry practices. Not all the needs of important users can be fulfilled
by current practices; hence, the study explored how the situation can be improved,
through data, analysis, and visualization.
The proposed solution leverages the value of data, especially real-time condition
data, in assisting decision-making processes. The paper tries to avoid suggesting
sophisticated diagnosis and prognosis guidelines or processes that can only be used
by limited user groups. Efforts were made to keep the suggested approach simple
and logical, to view the overall condition and performance of all monitored systems
and access various analyses’ results from the integrated interface for decision
support. The proposed solution can be used to implement routine checks, to carry
out retrospective failure analysis, and to plan preventive and proactive maintenance
regarding ESD systems.
 10 P. Zhu, J.P. Liyanage, S. Jeeves- Condition and performance monitoring of ESD systems

In practical terms, it is not always the case that the most statistically likely failure
cause is the exact failure cause in low-demand systems. In many cases, the use of
expert judgements combined with the suggested solution can be more efficient. A
future study may explore how to build a machine-learning engine that can
complement experts’ judgements.

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