18 - David Wiseman

7/29/2019 18 - David Wiseman

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Condition Monitoring

Data To Onshore

BP Forties - First producing North Sea field, Onshore control viatelemetry

Abandoned due to limited data and speed of communications

BP Mill ler - Excel Based CM with 10 parameters sent onshore

OIL Majors started worrying about Network Security most/all NorthSea links closed.

North Sea Fibre, rolled out to BP Fort ies 2001. Linked to Norway forBackhaul to the UK (redundant link)

North Sea comms easily available and realtively cheap, widespreadData to Desktop

Condition Based Monitoring


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Intro

A brief history to CM in the offshore environmentHow CM works in the offshore sectorHigh regulatory framework and high expectations

Overview of SystemLive Demo


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Condition Monitoring

Offshore/Onshore

Simple Visual checks

Handheld readings taken, recorded in notebooks

Handheld via PDAs

Handheld Downloads to OnshoreData Onshore subject to Data Mining

Offshore Data sent directly onshore

Offshore Data reviewed and maintenance based on Data


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Regulations

DSEAR stands for the Dangerous Substances and

Explosive Atmospheres Regulations 2002.

Dangerous substances can put peoplesfrom fire and explosion. DSEAR puts duties on employers

and the self-employed to protect people from risks to theirsafety from fires, explosions and similar events in theworkplace, this includes members of the public who maybe put at risk by work activity.

safety at risk


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Regulations

PFEER regulations (1995)

the Prevention of Fire and Explosion and EmergencyResponse. They came into force 20th June 1995. They arelaw in the UK.

In summary these regulations state the person orcompany responsible for an installation is alsoresponsible for protecting persons on the installationfrom fire and explosion and securing effective emergencyresponse.

for offshore installations for


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Regulations

The Offshore Installations (Safety Case) Regulations 2005

Safety Case requires all MAH ~(Major Accident Hazards) be

indentified and controlled.

MAH Lead to Performance Standards ~ Performancestandards to SCE (Safety Critical Elements) ~ SCE to Individual

SIL (Safety Integrity Levels) ~(Other compliance routes areavailable).

SIL sets a PFD ( Probabil ity of failure on Demand ) SIL is from1e-1 to 1e-3. Using failure rates (Lamda D) and test intervals aPFD is calculated. Not testing within a short period is l ikely tolead to failure to meet a SIL. Condition based maintenance is achallenge for SIL


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Nexen Equipment Condition Monitoring

CondiMaintenance Management System andManagement Policy.

The CBM program centres arounddiagnmonitoring and diagnostics centr

off ice with access to a wide range of data types.

Bringing the relevant data to ex

expen

tion Based Monitoring (CBM) system that is integral with thealigns to the Nexen Reliability

the abil ity to perform machineryostics and proactive condition monitoring remotely. Onshore

e sited in the Nexen Aberdeen

perts for rapid analysis, avoiding

sive & time consuming mobilisation of personnel & equipment.


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ProcessCompressors

hOther

Assets

Power GenerationEquipment Air

Compressors

VerticalPumps

Dynamic vibration data andprocess variables

HeatExchangers

PipelineCompressors

Monitoring andDiagnosticCenter

24/7/365 DedicatedExpertise

Operations, Maintenance, &EngineeringProactive

Advisories

CorrectiveA

ction Smart Decision SupportSM softwarescreens incoming data

Field-experienceddiagnostics engineers

Early detection ofanomalies

Proactive Operations &Maintenance Actions

PumpSets

Asset Equipment Condition Monitoring System1


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System1 High Crit icality Machines (30 machines) Vibration (amplitude, frequency and phase), temperature and process data from

installed transducers continuously recorded and monitored by System1

Thermodynamic performance calculated every 30 seconds and compared withmanufacturers stated performance values. Corrections made for ambient and sitespecific conditions (gas composit ion changes, etc)

Dry Gas Seal monitoring on all centri fugal compressors

Machine run hours continuously recorded by System1

Decision Support RulePaks continuously analysing available data for a range ofmachine specific faults

System1 Balance of Plant (~150 machines)

Vibration (amplitude & frequency), bearing temperature and process data measuredperiodically using a portable data col lector and uploaded to System1 database.

Machine run hours continuously recorded by System1


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System1 Other Assets & Functionality Heat exchanger performance monitor ing

Corrosion monitoring util ising installed transducers

Product ion and availability data

Leaks and weeps monitoring

PEMS - real time turbine exhaust gas emissions monitor ing utilis ing model data andthermodynamic calculations


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Total Exceptions Raised During Last 12 Months - 139

Level 1 Low: Fault requires corrective action. Not likely to result in immediate equipment failure.

Level 2 - Medium: Incipient fault, which is likely to result in equipment failure.Level 3 - High: Significant potential to cause loss of production if fault is not rectified or equipmentremoved from service immediately.Instrument Fault: Instrument fault which may result in equipment shutdown/lost production if not rectified atthe earliest opportunity.



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Condition Monitoring Thermography Program

Thermography Routine Thermographic surveys to monitor temperatures across rotating equipment

Routine Thermographic surveys to identify incipient faults on electrical switchgear

Routine Thermographic surveys of process equipment to help identify such things

as heat exchanger fouling, passing valves, etc

Offshore Reliabili ty Technicians formally trained in Thermography data col lectionand analysis. Flir hardware and analysis tools uti lised and data stored in System1using Docuview function


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Total Exceptions Raised During Last 12 Months - 43

Asset Equipment Condition Monitoring Thermography Program


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Asset Fluid Analysis

Fluid Analysis Routine sampling of lubrication, fuel and seal fluids to monitor condition and to

identify contamination and degradation

Database available on-line to monitor trend data and recommendations


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Asset Equipment Condition Monitoring Fluid Analysis

Total Exceptions Raised

During Last 12 Months - 43


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Asset Equipment Condition Monitoring Electrical Techniques

Electrical Techniques Periodic Partial Discharge testing of critical machines util ising installed Rogowski

coils to monitor stator condition

Periodic Rotor Current Waveform analysis of critical motors to monitor rotorcondition

Feasibil ity to connect electr ical relays (GE Mult iLin) to System1 for continuous realtime motor rotor current signature analysis

UPS condit ion monitoring system


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Electric Motors - Rotor Current AnalysisNumber of machines tested: 311 Exception (no invasive action required)

Electric Motors - Partial Discharge AnalysisNumber of machines tested: 24

4 Exceptions (no invasive action required)

Asset Equipment Condition Monitoring Electrical Techniques

Documents

18 - David Wiseman