COMPASS The world s only and fully Integrated Machine

COMPASS The world’s only and fully ‘Integrated Machine Monitoring System’ Concepts and Applications Power Plants Petrochemical Plants Oil & Gas Industry Heavy Process Industries * Page

Presentation, Content & Structure • Bruel & Kjaer Vibro (BKV) & Thomassen Compression Systems (TCS), together in Reciprocating Compressor Monitoring • Purpose of Integrated Monitoring • Function of Monitoring Systems – Safety Monitoring – Condition Monitoring • System Configuration – Communication Links – Integration with DCS • Benefits for: – Machine Vendors – End-Users – System Integrators (DCS, Contractors) 2

Machine Protection, Condition and Performance Monitoring Systems Total Reciprocation Compressor Monitoring A Co-operation between Condition Monitoring Systems And 3

Integrated Monitoring, all historic data available Mechanical Shafts/Bearings • Shaft vibration • Shaft displacement • Bearing wear debris • Bearing temperature Stator/blades/casing • Vibration • Temperature • Clearance Other • Motor current • Partial discharge • Winding temperature Etc. Process • Inlet/outlet temperature • Inlet/outlet pressure • Valve temperature • Flow • Speed • Power • Running hours • Etc. Performance • Efficiency • Head • Pressure ratio • Energy balance • Etc. 4

Monitoring Principle The BKV - TCS philosophy for “Integrated Machine Monitoring” Distinction between: Measuring – Measuring requires human interpretation of current measurements Monitoring – Monitoring is a completely automated comparison between the current and reference measurements 5

System Overview 6

System Concepts • Reduce No. of components in LIM – only 4 different modules, programmable inputs – no 4 -20 m. A output, but Software link (Modbus) • Reduce No. of LIMs – multiple machines in single LIM – high density of channels in one LIM, up to 112 channels for multiplexed I/O – smart Relays where multiple input signals can switch the Relay • Reduce Network Load – – event based data storage analyzer in LIM, no need tot transfer time signals over network, alarm generation in LIM DTF File (simple ASCII Format) to transfer Process data from DCS to CCS • Increase Reliability and Stability – Dual Power Supply – Relay (de)activation in LIM, no computer needed – Continuos self testing of LIM functionality 7

Safety Monitoring Condition Monitoring Purpose of Safety Monitoring Purpose of Condition Monitoring Goal: To avoid dangerous situations for man, environment and machine Goal: Detect potential machine problems in an early stage of development Action: Trip just before moment of danger Action: Software warning in an early stage of development Maintenance strategy: ‘Run to almost break’ Maintenance strategy: Condition based Co-ordination with production: No Co-ordination with production Yes 8

Safety Monitoring Condition Monitoring Prevent catastrophic damage Monitor machine condition But. . • NO indication of machine condition • NO warning • NO post analysis • NO remote access Therefore… • Early warning • Fault analysis • Machine condition is always known Result… • Lost production • Faults continue to occur Result… • Improved machine availability • Prevent futher failures Vibration Danger Alarm level Fault detected Lead time for repair Machine stopped Time 9

Condition Monitoring Techniques • • • CPB spectrum FFT spectrum SED Cepstrum Rod Drop AMS, Adaptive Monitoring Strategy – Process classes in order to monitor under equal Process Condition • Alarm on all Spectral Measurements, Real Monitoring instead of Measuring. • Transient Monitoring • No International Standards available 10

Condition Monitoring, Alarm on Spectrum 11

Condition Monitoring Systems - Drawback comments • Nice pictures, but only experienced experts can analyse vibration data • Machine vibration changes with operating conditions • Need to be on site to work with system • Long term data storage is inpractical 12

Monitoring at a glance • COMPASS uses alarm traffic lights to give users an instantaneous overview of machine condition. RED - DANGER STATE YELLOW - ALERT STATE GREEN - NORMAL STATE BLUE - SYSTEM ALARM 13

Monitoring at a Glance 14

Change of Operating Condition? Overlay Plots answer 15

Remote Access via the Internet 16

Data Storage Based on Events instead of Time 17

COMPASS, Automatic Alarms on Result 18

Reciprocating Compressors, 2 point Rod Drop 19

Built-in smoothing techniques 20

Reciprocating Compressors, Relative Deviation Result 21

Reciprocating Compressor Performance 22

Reciprocating Compressor Performance 23

Reciprocating Compressor Performance 24

Why BKV - TCS? Implementing COMPASS means: – Implementing a proven system which Integrates Safety, Condition and Performance Monitoring – Implementing a System with full backup of machine vendor (Thomassen Compression Systems) – A system built for reliable trending and predictive maintenance – The use of unique and advanced condition monitoring techniques – The use of unique and advanced Performance Monitoring techniques – Project Implementing a system conform ISO 9001 standards References General: – – – – Statoil Norway Kollsnes Norway PDO Upstream facilities Oman LNG Woodside LNG Australia Nigeria LNG Hoekloos Netherlands References Recip Compressor: – Bulwer Island – Woodside LNG – NAM (5 plants) 25

Investing in Integrated Monitoring Systems! The question is not: ‘Can I afford to invest in an Integrated Monitoring System? ’ but: ‘Can I afford not to invest in an Integrated Monitoring System? ’ Being better then the rest 26