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Integrated Machine Monitoring System': Concepts and Applications

The document describes the COMPASS integrated machine monitoring system from Bruel & Kjaer Vibro and Thomassen Compression Systems. It provides integrated monitoring of mechanical, process, and performance parameters. The system aims to provide safety monitoring to avoid dangerous situations and condition monitoring to detect potential machine problems early. It features remote access, event-based data storage, automatic alarms, and built-in data analysis techniques. The document argues that investing in an integrated monitoring system can improve machine availability and prevent failures through early warning.

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akamalapuri388
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Download as PPS, PDF, TXT or read online on Scribd
114 views

Integrated Machine Monitoring System': Concepts and Applications

The document describes the COMPASS integrated machine monitoring system from Bruel & Kjaer Vibro and Thomassen Compression Systems. It provides integrated monitoring of mechanical, process, and performance parameters. The system aims to provide safety monitoring to avoid dangerous situations and condition monitoring to detect potential machine problems early. It features remote access, event-based data storage, automatic alarms, and built-in data analysis techniques. The document argues that investing in an integrated monitoring system can improve machine availability and prevent failures through early warning.

Uploaded by

akamalapuri388
Copyright
© © All Rights Reserved
Available Formats
Download as PPS, PDF, TXT or read online on Scribd
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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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