Urgent - Pennsylvania State University · 2015-10-15 · – According to Energy Matters, a...

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Urgent Vibration Applications in Oil & Gas

and Industrial Manufacturing

Jeremy Frank, PhD President, KCF Technologies, Inc.

April 27, 2015

Impact of Poor Maintenance Practices

• $750 Billion/year wasted (poor repair and maintenance) – According to Energy Matters, a magazine published by the DoE

• $2,400 Billion/year wasted (collateral damage) - According to DoE’s Advanced Manufacturing Office

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Vibration Expertise is in Need

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Easy (but lower value) 10 sensors 1 minute setup 1 hrs/month

Challenging (but higher value) 100 sensors 50 minute setup >100 hrs/month

Most Maintenance Programs are Flawed

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(Source: Wheeler, “Align Facilities Engineering Objectives with Business Goals to Improve Results and Eliminate Wasted Time and Money,” 2007)

• Fallacy of Preventive Maintenance

Example: Paper/Pulp Liquor Pumps

• Problem: Premature motor/pump failure

• Solution: Detect Root Cause (Process Change)

Alarm Shut-Down

Paper Coating: Re-Reeler

Rereeler Data – Actionable Information

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Benefits of Information

1. Quantify suspect condition (noise/vibration)

2. Localize and diagnose areas of concern (gearbox axial)

3. Enable and confirm redesign (collaborate)

4. Optimize preventive maintenance

#7 Paper Machine – Center Roll Gearbox

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Gear Mesh Sideband (load, backlash, wear)

Oil & Gas – Pressure Pumping Site

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Damage/Vibration Comparison Between Fleets

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Fluid End – Failure @ 50 hours

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“…fluid end has less than 50 hours on it, and the surface where the side cap seals on the middle suction bore is worn. This is causing leaking during the stage, which means it’s sucking air through this hole and causing cavitation.”

• Running pumps in 4th gear results in much higher vibration and is suspected to have caused iron mount bolt failures.

Pumps in 4th Gear = Increased Damage

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Example of a pump which ran in 3rd gear for and then was changed to 4th gear, which may have caused an iron mount failure.

Improved Safety in the Marcellus – Reduction of Incidents (NPT)

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Fluid End Hours

Pump Truck Hours/Baseline##01 112%##02 145%##03 120%##04 240%##05 14%##06 266%##07 206%##08 121%##09 135%##10 69%##11 257%##12 203%##13 302%##14 200%##15 160%

Average 170%