COMPASS
The world’s only and fully
‘Integrated Machine Monitoring System’
Concepts and Applications
Power Plants Petrochemical Plants Oil & Gas Industry Heavy Process Industries
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)
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Machine Protection, Condition and Performance Monitoring Systems
Total Reciprocation Compressor Monitoring
A Co-operation between
Condition Monitoring Systems
And
T H O M A S S E N
C O M P R E S S I O N
S Y S T E M S
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Integrated Monitoring, all historic data available
Mechanical Process Performance
Shafts/Bearings •Inlet/outlet temperature •Efficiency
•Shaft vibration •Inlet/outlet pressure •Head
•Shaft displacement •Valve temperature •Pressure ratio
•Bearing wear debris •Flow •Energy balance
•Bearing temperature •Speed •Etc.
Stator/blades/casing •Power
•Vibration •Running hours
•Temperature •Etc.
•Clearance
Other
•Motor current
•Partial discharge
•Winding temperature
Etc.
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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
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System Overview
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System Concepts
• Reduce No. of components in LIM
– only 4 different modules, programmable inputs
– no 4-20 mA 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
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Safety Monitoring Condition Monitoring
Purpose of Safety Monitoring Purpose of Condition Monitoring
Goal: Goal:
To avoid dangerous situations for man, Detect potential machine problems in an
environment and machine early stage of development
Action: Action:
Trip just before moment of danger Software warning in an early stage of
development
Maintenance strategy: Maintenance strategy:
‘Run to almost break’ Condition based
Co-ordination with production: Co-ordination with production
No Yes
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Safety Monitoring Condition Monitoring
Prevent catastrophic damage Monitor machine condition
But.. Therefore…
• NO indication of machine condition • Early warning
• NO warning • Fault analysis
• NO post analysis • Machine condition is always known
• NO remote access
Result… Result…
• Lost production • Improved machine availability
• Faults continue to occur • Prevent futher failures
Vibration Vibration
Danger Alarm level
Fault detected
Machine stopped Lead time
for repair
Time
Time
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Condition Monitoring
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
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Condition Monitoring, Alarm on Spectrum
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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
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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
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Monitoring at a Glance
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Change of Operating Condition? Overlay Plots answer
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Remote Access via the Internet
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Data Storage Based on Events instead of Time
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COMPASS, Automatic Alarms on Result
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Reciprocating Compressors, 2 point Rod Drop
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Built-in smoothing techniques
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Reciprocating Compressors, Relative Deviation Result
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Reciprocating Compressor Performance
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Reciprocating Compressor Performance
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Reciprocating Compressor Performance
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Why BKV - TCS?
Implementing COMPASS means: References General:
– Implementing a proven system – Statoil Norway
which Integrates Safety, Condition – Kollsnes Norway
and Performance Monitoring – PDO Upstream facilities Oman
– Implementing a System with full – Oman LNG
backup of machine vendor
(Thomassen Compression – Woodside LNG Australia
Systems) – Nigeria LNG
– A system built for reliable trending – Hoekloos Netherlands
and predictive maintenance
– The use of unique and advanced References Recip Compressor:
condition monitoring techniques
– The use of unique and advanced
Performance Monitoring – Bulwer Island
techniques – Woodside LNG
– Project Implementing a system – NAM (5 plants)
conform ISO 9001 standards
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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
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