critical equipment management workshop
DESCRIPTION
Critical Equipment Management WorkshopTRANSCRIPT
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Kenneth St Brice
Critical Equipment Management Workshop
Overview of Rashpetco Operations
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Rashpetco - Asset Overview
Daily Production• Gas - 2 BCFD• Condensate – 4500 BPD• Aqueous – 14,000 BPD
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Organisation Overview - Condition Monitoring Set Up
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Maintenance Gen Manager
Instrument AGM
District Field Gen. Mgr
Technical Gen. Mgr
Production Gen Manager
Turbomachinery AGM
Planning AGM Electrical AGM
Inspection Gen Manager
- Site Operations
Operations Manager
Condition Monitoring
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Asset Critical Equipment Infrastructure
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Number of Critical Rotating Equipment
ROSETTA
6 Gas Turbines
4 Generators
2 Compressors
WEST DELTA DEEP MARINE
13 Gas Turbines *
6 Generators *
7 Compressors *
1 Reciprocating Gas Compressor
* Phase VII Equipment yet to be commissioned.
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Asset Infrastructure Overview
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• What Equipment Monitoring Systems Are Used Today?
– No Historian – No Remote Monitoring
◦ For Siemens SGT 400 Booster OEM Compressors - local monitoring performed using BN 3500 data
– Specialist systems◦ Vibration Monitoring – Rockwell ENPAC / EMONITOR◦ Lube Oil Monitoring◦ Electrical Infrared Monitoring◦ Bently Nevada System I planned for Phase VII◦ System I planned for extension across plant
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History
• July 2009 – Fire on Heating Medium Pump @ CCR MEG Recovery Plant (Contract Plant)
• RCA pointed to bearing failure, seal failure, hot oil leak and fire as the sequel to the event.
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Analysis performedVibration and Spike Energy Assessment
Conclusion and ResolutionBy successful intervention the CM Team:• Avoided a repeat heating medium fire
incident on plant• Saved significant cost due to escalation
failures on seal, shaft, housing etc.• Built significant credibility shortly after
commencement of work as a team.
Success Story at Site
Event
• Condition Monitoring Team set up – March 2010
• In May 2010 – Carried out routine monitoring of WDDM Heating Medium Pump.
• Ascertained that bearing was in pending failure
• Recommended bearing change
Spall on bearing inner race
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Current Problem Being Experienced
WDDM Booster Compressor - High Vibration• Booster Compressor trains have shown high and erratic
vibration patterns from installation. • The Gas Generator inlet end bearing been showing high
vibrations for the last 6 months. The vibration has been predominantly on the B machine but recently we have seen increases also on the A Gas Generator.
• The impact of the higher vibration has been to limit the machine speed which impacts deliverability.
• The OEM has changed out the Train B engine during a recent shutdown to carry out further diagnosis at their workshop.
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GG Inlet Bearing – 20th May 2010 GG Inlet Bearing – 20th May 2010
GG Inlet Bearing – 27th Oct 2010 GG Inlet Bearing – 27th Oct 2010
Current Problem Being Experienced