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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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Asset Equipment Condition Monitoring System1
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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Asset Equipment Condition Monitoring System1
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.
Asset Equipment Condition Monitoring System1
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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