BREAK OUT GROUP 1 MONITORING SYSTEMS

Transcription

1 BREAK OUT GROUP 1 MONITORING SYSTEMS Innospec Leuna GmbH Mirko Graf PROGNOST Systems GmbH Udo Wilmes

2 Agenda About Innospec Leuna / Ltd. & PROGNOST Systems GmbH Hyper Compressor Condition Monitoring System Plunger Position Sensors Intermediate Crosshead Monitoring Strain Gauge Measurements Vibration Sensors on Main Bearings Page 2

3 Plants INNOSPEC General Information Salisbury (NC/US) High Point (NC/US) Oklahoma City (OK/US) Chatsworth (CA/US) Pleasanton (TX/US) Midland (TX/US) Ellesmere Port (UK) Vernon (FR) St. Mihiel (FR) Castiglione (IT) Barcelona (ES) Herne (DE) Leuna (DE) Representatives Corporate Headquarter Englewood/Denver (CO/US) Ellesmere Port (UK) Madrid (ES) Milan (IT) Piraeus (GR) Limassol (CY) Everberg (BE) Karlstad (SE) Moscow (RU) Rio de Janeiro, Itajai (BR) Houston (TX/US) Cape Town (ZA) Dubai (UAE) New Delhi (IN) Seoul (KR) Beijing, Guangzhou (CN) Hong Kong (HK) Additional Info Technology Centres Pencader (DE/US) Salisbury (NC/US) Houston (TX/US) Millbrook (UK) Singapore (SG) Castiglione (IT) Ellesmere Port (UK) Everberg (BE) Employees: 1,800 (2017) Turnover: $1.3b (2017) Fuel Specialties Oilfield Services Performance Chemicals Octane Additives Page 3

4 Innospec Leuna Plant and Products EVA Tubular Reactor Commissioning in 1968 as Pilot Plant Hydraulically-driven Hyper Compressor EVA FLEXAREN Injection moulding Sheets / profiles Flexible hoses Films Foams Carrier material Compounds PE/EVA WAX VISCOWAX Additives for: PVC processing Masterbatches Printing inks Lacquers Hot melt adhesives Road marking Candles/Paraffine compounds Bitumen/asphalt EVA Cold Flow Improver Diesel Fuel Heating Oil Page 4

5 Company Profile PROGNOST is the technological leader in machine protection and online monitoring for rotating equipment providing remote diagnostics with an experience of more than 25 years. Page 5

6 Company Profile Headquarter: Rheine (GER), subsidiary: Houston (USA) Total no. employees: 85 Global network of 40 sales and distribution partners for responsive and local on-site support Page 6

7 PROGNOST -NT in a Nutshell Automated machinery diagnostic system Machine protection (MPS) and online condition monitoring (CMS) For reciprocating machinery and for all rotating equipment Assigns the affected components and detects failures very early Operation-critical damages are avoided and maintenance measures can be performed efficiently Page 7

8 Hyper Compressor Monitoring What are the options for Hyper compressor monitoring? PROGNOST -NT Condition monitoring Interm.crosshead Plunger position Machine protection p-v diagram (indirect) Cylinder vibration Process data e.g temperatures PROGNOST -SILver Page 8

9 Typical Sensor Positions for a New Hyper Page 9

10 Example: Hydraulically-driven Hyper at Innospec Manufacturer: Burckhardt Compression Commissioning in Stages / 6 Cylinders Hydraulic Load Transmission SP = 250 bar, DP = 2,350 bar Gas pistons with piston rings Page 10

11 Retrofitted Condition Monitoring System Resistance Strain Gauges Vibration Sensors Plunger Position Sensors Pressure Transmitters Vibration Sensors Trigger Sensor Vibration Sensors Pressure Transmitters Vibration Sensors Mass Flow Meters Page 11

12 Plunger Position Sensor Standard assembly on Hyper machines Plunger position sensors are useful to identify broken plungers and packings as well as polymer blockages Normally such sensors can easily be implemented in the outer area of the safety packing flange Page 12

13 Retrofitting Plunger Runout Sensors I At a hydraulically-driven Hyper Compressor the piston nut is able to override its final position by specific failures of the hydraulic oil pumps, which deliver the oil pressure of about 300 barg. An electric failure led to a crush of totally 6 sensors after 3 months of operation. Improvements to the sensor implementation were required. Page 13

14 Retrofitting Plunger Runout Sensors II Sensor adaptors are installed into the lid of the safety packing gland. Page 14

15 Intermediate Crosshead Monitoring PROGNOST -NT Condition monitoring Interm. crosshead Plunger position p-v diagram (indirect) Cylinder vibration Process data Machine protection PROGNOST -SILver Page 15

16 Case Study 1: Loose plunger Coupling - Trend Maximum value (every minute) Protection limit (every rotation) Minute average 2 nd warning threshold (min. average) 1 st warning threshold (min. average) Page 16

17 Case Study 1: Segmented Crosshead Vibration Page 17

18 Case Study 1: Learnings Intermediate crosshead vibration provides early detection of looseness in plunger connections Major machine damage can be avoided Only segmented vibration analysis allows an effective monitoring of single vibration events within one rotation Page 18

19 Intermediate Crosshead Monitoring PROGNOST -NT Condition monitoring Interm. crosshead Plunger position p-v diagram (indirect) Cylinder vibration Process data Machine protection PROGNOST -SILver Page 19

20 Strain Gauge Measurement Cylinder pressure signals (p-v diagram) by strain gauge measurement on a Hyper compressor is a unique feature of PROGNOST-NT systems Different possibilities for installation such as strain gauge bolts/ -rings/ -blocks in diverse forms of application Page 20

21 Strain Gauge Application Page 21

22 Valve Activity Strain Gauges I To depict the Valve Activity: one Vibration Sensor and normally two Strain Gauges are required on each cylinder. Furthermore one Trigger sensor for the entire machine is required. Normally the Strain Gauges are easy to implement on the exposed cylinder bolts. The hydraulically-driven Hyper has cylinder bolts only on the interior side -> a customised solution was required. Page 22

23 Valve Activity Strain Gauges II 1 st Approach: Prolonged cylinder bolts for the inclusion of a distance bush to implement the Strain Gauges. RESULT: Signals were too weak and could not be used. 2 nd Approach: Modified distance bushes containing a machined out strain area. RESULT: No improvements to signals. Page 23

24 Valve Activity Resistance Strain Gauges III 3 rd Approach: Full examination of the entire cylinder to find a place to install the Strain Gauges. RESULT: One unexpected location was found on cylinder housing. RESULT: Reliable signal output! Page 24

25 Case Study 2: Vibration Sensors on Main Bearings I An early detection of a starting failure at one of the main bearings was possible by the vibrations sensors. Overheating traces at the upper bearing shell. Starting material fractures at the lower bearing shell. Cause of damage: temporarily inadequate lubrication of bearing. Page 25

26 Case study 2: Vibration Sensors on Main Bearings II Upper bearing shell. Lower bearing shell. An early detection of a starting failure at one of the main bearings was possible by the Vibrations Sensors. Overheating traces at the upper bearing shell. Starting material fractures at the lower bearing shell. Cause of damage: temporarily inadequate lubrication of bearing. Page 26

27 Innospec Leuna GmbH Mirko Graf Prognost Systems GmbH Udo Wilmes