Paradigm Shift Detection of Deviation_Swapnil Sharma
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The document discusses early detection of deviations from operating parameters to extend plant availability. It describes monitoring electrical and mechanical assets like pumps, valves and heat exchangers during turnarounds to identify deviations from acceptable thresholds. Using condition and performance monitoring tools in addition to preventative maintenance can help extend plant uptime. The document also discusses a case study of detecting issues in a heat exchanger by monitoring parameters like pressure, temperature and vibration trends. Corrective actions like cleaning tubes helped resolve the problems and normalize operations.
Paradigm Shift Detection of Deviation_Swapnil Sharma
- 1. © 2015 Cairn India Limited Paradigm Shift : Early detection of deviations from operating parameters to extend plant availability Swapnil Sharma Maintenance Manger Cairn India Ltd
- 2. 2 Preventing turnaround failures Early detection of deviations from operating parameters andEarly detection of deviations from operating parameters andEarly detection of deviations from operating parameters andEarly detection of deviations from operating parameters and monitoring electrical and mechanical assets during a turnaround tomonitoring electrical and mechanical assets during a turnaround tomonitoring electrical and mechanical assets during a turnaround tomonitoring electrical and mechanical assets during a turnaround to extend plant availabilityextend plant availabilityextend plant availabilityextend plant availability Surveying performance monitoring of mechanical assets like pumps, valves, heat exchangers and turbo compressors to identify deviation from acceptable thresholds Using condition and performance monitoring tools apart from preventive and predictive maintenance diagnostics to extend plant availability Integrating asset monitoring software with alarm management to understand diagnostic functions and impact of deviation
- 3. 3 Detection of Deviation : A processDetection of Deviation : A processDetection of Deviation : A processDetection of Deviation : A process
- 4. 4 Making the Detection of Deviation ExplicitMaking the Detection of Deviation ExplicitMaking the Detection of Deviation ExplicitMaking the Detection of Deviation Explicit There is an almost universal quest for easy answers and half-baked solutions……………………..Martin Luther King, Jr. Making the deviation Explicit Dealing with uncertainty Identifying alternatives Rationalising the deviation Deviation Statement Goal Tree Causal diagram SMART Deviation diagram Triangulation Scenarios Impact-Table Score-Card estimates NPV equations Conceptualisation Complex plant with complex problems Rationalisation Professional group decision-making support – bringing actors together
- 6. 6 Making an Overview : ConceptualizeMaking an Overview : ConceptualizeMaking an Overview : ConceptualizeMaking an Overview : Conceptualize
- 7. 7 Frame DeviationFrame DeviationFrame DeviationFrame Deviation SSSStatementtatementtatementtatement
- 8. 8 Causal Diagram : Underperformance 155 160 165 170 175 Discharge pressure (bar)Discharge pressure (bar)Discharge pressure (bar)Discharge pressure (bar) Discharge pressure (bar) 3800 3900 2nd June 23rd June 20th July 12th August RPM Pump performance comparison for turbine driven power fluid pumps. Decrease in discharge pressure observed at same RPM
- 9. 9 Identify problem Triangulation :Comparing Trends Normal Trend Before Inspection Trend showing abnormality Normal trend after corrective maintenance Corrective repair job being carried out
- 10. 10 Traingulation Data Analysis through System 1: Normal Trend Before Inspection Increasing trend showing abnormality Normal trend after Maiaintenance PANEL OBS. : Decrease in throughput and discharge pressure
- 11. 11 Culprit fixation through Orbit plot : Distortion in orbit indicating restriction in shaft movement due to improper fluid dynamics( bearing oil or process fluid) Normal plot Turbine Plot Before Turbine Plot After Pump Plot Before Pump Plot After
- 12. 12 Elimination of uncertainties :Problem Eradication Confirmation Through Waterfall plot Sub-harmonics observed before inspection showing abnormalities Plot showing pump in healthy condition
- 13. 13 Another Example : Heat ExchangerAnother Example : Heat ExchangerAnother Example : Heat ExchangerAnother Example : Heat Exchanger
- 14. 14 GA of Injection Water Heater: ConceptualizeGA of Injection Water Heater: ConceptualizeGA of Injection Water Heater: ConceptualizeGA of Injection Water Heater: Conceptualize url.htm
- 15. 15 Technical Data: Making deviation ExplicitTechnical Data: Making deviation ExplicitTechnical Data: Making deviation ExplicitTechnical Data: Making deviation Explicit FluidFluidFluidFluid AllocationAllocationAllocationAllocation ShellShellShellShell sidesidesideside TubeTubeTubeTube sidesidesideside Steam Produced Water Fluid Quantity, total (kg/hr.) 97775.4 1476407 Fluid Name 97775.4 Water (In/Out) kg/hr. 97775.4 1476407 1476407 Temperature °C (In/Out) 170.10 169.57 57.10 88.00 Inlet Pressure kPa 790.012 900.013 Velocity m/s 4.60 1.39 Pressure Drop, Allow/Cal kPa 15.000 6.043 70.001 16.436 Fouling Resistance (min.) m2K/W 0.000176 0.000352 Heat Transfer Rate , W/mHeat Transfer Rate , W/mHeat Transfer Rate , W/mHeat Transfer Rate , W/m2222KKKK ServiceServiceServiceService---- 772.69 W/m772.69 W/m772.69 W/m772.69 W/m2222KKKK CleanCleanCleanClean---- 2150.55 W/m2150.55 W/m2150.55 W/m2150.55 W/m2222KKKK ConstructionalConstructionalConstructionalConstructional ParametersParametersParametersParameters Shell SideShell SideShell SideShell Side Tube SideTube SideTube SideTube Side Design Pressure kPaG 1800 1800 Design Temperature °C 220 220 No. of passes per shell 1 1 No. of tubes : 2116 Tube O.D. : 19.05mm Average Thickness of tube : 2.77mm Length of tube : 6.096mm Material of tube : CR-NI-FE-MO-CU-CB Alloy 20 CB Shell I.D. : 1296mm
- 16. 16 What happened ????...... Deviation StatementWhat happened ????...... Deviation StatementWhat happened ????...... Deviation StatementWhat happened ????...... Deviation Statement Fouling or Scaling : Calcium carbonate/phosphate/sulfate, silica, salts, corrosion products Additional resistance to reduce operational capability Increased pressure drop Unprecedented hardness Tubular deposition, typically at both ends effectively1M length and in 358/2116 no’s of tubes.
- 17. 17 Some statistical data…..Deviation DiagramSome statistical data…..Deviation DiagramSome statistical data…..Deviation DiagramSome statistical data…..Deviation Diagram Effective time of tube cleaning > 2 hrs./tube (excessive hard). Historically the cleaning has never took more than 6 days. 0 2 4 6 8 10 12 14 16 11/12/2010 3/1/2011 15/3/2011 17/6/2011 2/9/2011 12/10/2011 27/11/2011 1/4/2012 29/1/2012 18/2/2012 10/3/2012 18/5/2012 28/7/2012 15/8/2012 29/8/2012 18/9/2012 8/10/2012 E-415B Cleaning Days What about tools??.....What about tools??.....What about tools??.....What about tools??.....
- 18. 18 MPTMPTMPTMPT---- Chemical Lab Report: Causal DiagramChemical Lab Report: Causal DiagramChemical Lab Report: Causal DiagramChemical Lab Report: Causal Diagram Lab ReferenceLab ReferenceLab ReferenceLab Reference #### MPT/LAB/SS/2012/July/036MPT/LAB/SS/2012/July/036MPT/LAB/SS/2012/July/036MPT/LAB/SS/2012/July/036----038038038038 S.NoS.NoS.NoS.No Parameters Unit s Sample" A" Sample" B" Sample" C" 1111 Appearance - Grey hollow tubular Brownish flakes Soft black cylindrical 2222 Toluene Soluble (Hydrocarbons) % 5.91 15.94 31.63 3333 Acid Soluble % 88.68 76.37 55.83 4444 Acid Insoluble % 5.41 7.69 12.54 5555 Iron in acid soluble as Fe % 3.89 38.64 23.30 6666 Calcium in acid soluble as CaCO3 % 94.3794.3794.3794.37 Absent Absent 7777 Sulfate in acid soluble % 0.25 Traces Traces 8888 Spot test with con.HCl - Effervescence confirms presence of carbonate Effervescenc e with H2S smell Effervescenc e with H2S smell 9999 Magnetic nature - Non magnetic Magnetic Partially magnetic RemarksRemarksRemarksRemarks CaCO3 scale mostly Oil coated Iron oxide, Iron sulfide flakes Oil coated Iron sulfide schmoo The deposits collected was segregated in three portions according to the difference in appearance and was checked for composition.
- 19. 19 How to clean these tubes???...... TriangulationHow to clean these tubes???...... TriangulationHow to clean these tubes???...... TriangulationHow to clean these tubes???...... Triangulation • HydroHydroHydroHydro----jettingjettingjettingjetting: conventional mechanical cleaning • MultiMultiMultiMulti----lancinglancinglancinglancing: rigid high-pressure multiple lances, operator controlled . 10,000 psi up to 40,000 psi, three times faster. lance moves into the tube bundle with up to 400 lb. force. • Chemical Injection:Chemical Injection:Chemical Injection:Chemical Injection: Sulphamic Acid is super efficient descaling agent • ATCSATCSATCSATCS: Automated tube Cleaning System online cleaning of the tubes Measures to prevent scaling: Dealing uncertaintiesMeasures to prevent scaling: Dealing uncertaintiesMeasures to prevent scaling: Dealing uncertaintiesMeasures to prevent scaling: Dealing uncertainties • Online Heat exchanger cleaning (soft ball cleaning system) • Installation of Water filter before the heat exchanger (having back wash arrangements). • Skimming of oil at Injection Water Tank (omni directional pivoted arm skimming arrangement). • Increased backwash frequency. • Preheating of Injection water (prior to u/s of heater, ie steam heating coils in the Injection water Tank) • Low operational pH : an effective way to prevent Calcium Carbonate formation • Engineered Scale inhibitors: that being adsorbed on the surface of calcium carbonate causing delay of crystal growth at very early stages.
- 20. 20 Page 20 Integration of Asset Management Software with AlarmIntegration of Asset Management Software with AlarmIntegration of Asset Management Software with AlarmIntegration of Asset Management Software with Alarm Management System :ConsiderationsManagement System :ConsiderationsManagement System :ConsiderationsManagement System :Considerations A combination of hardware,hardware,hardware,hardware, softwaresoftwaresoftwaresoftware andandandand servicesservicesservicesservices used to assess the healthhealthhealthhealth ofofofof plantplantplantplant assetsassetsassetsassets by monitoring asset condition periodically or in real-time to identify potentialpotentialpotentialpotential problemsproblemsproblemsproblems before they affectaffectaffectaffect thethethethe processprocessprocessprocess or lead to a catastrophiccatastrophiccatastrophiccatastrophic failurefailurefailurefailure. Plant Measurements & Historian Information Control Systems PAM EAM / CMMS Maintenance Operations * EAM: Enterprise Asset Management CMMS: Computerized Maintenance Management system AM Information Flow AM Systems EAM CMMS Real-Time AM Systems RealRealRealReal----timetimetimetime predictive asset health information with an intelligentintelligentintelligentintelligent analyticalanalyticalanalyticalanalytical engineengineengineengine to predict potential asset problems
- 21. 21 Audit Trail Maintenance Information Management AssetAssetAssetAsset Monitoring SoftwareMonitoring SoftwareMonitoring SoftwareMonitoring Software ---- Integrated Platform forIntegrated Platform forIntegrated Platform forIntegrated Platform for Maintenance & DiagnosisMaintenance & DiagnosisMaintenance & DiagnosisMaintenance & Diagnosis Core Integrated Maintenance Platform Device status viewing Tuning, Adjustment & Calibration Maintenance Alarm Diagnostics Online Maintenance Core Predictive Diagnostics Core
- 22. 22 Rate per Operator Acceptability > 1 per minute Unacceptable 1 per 2 minutes Likely Over- Demanding 1 per 5 minutes Manageable 1 per 10 minutes Acceptable Some TargetsSome TargetsSome TargetsSome Targets----Where Do You Stand?Where Do You Stand?Where Do You Stand?Where Do You Stand? You either have a working alarm system or another distraction for operators in the control room. Alarms are intended to forewarn of an event that could lead to major equipment damage, business interruption, safety concern, or environmental risk. Alarms should require immediate operator attention, provide a critical layer of safety, minimize the demands on emergency shutdown systems, diagnose problems before they escalate, and quickly guide operators to clear corrective action. Source: EEMUA 191 Good Alarm Characteristics Relevant Unique Timely Prioritized Understandable Diagnostic Advisory Focusing
- 23. 23 Alarm NotificationAlarm NotificationAlarm NotificationAlarm Notification ---- Device DiagnosisDevice DiagnosisDevice DiagnosisDevice Diagnosis ((((Device ViewerDevice ViewerDevice ViewerDevice Viewer function)function)function)function) Normal Abnormal
- 24. 24 Alarm NotificationAlarm NotificationAlarm NotificationAlarm Notification –––– Maintenance AlarmMaintenance AlarmMaintenance AlarmMaintenance Alarm (Blue) GE System 1 Status -Device to be investigated (Orange) GE System 1 Status – Device Non Critical Icon Detail (Green) Healthy by Device Patrol (Red) Maintenance alarming by Device patrol (Yellow) Maintenance Warning By Device patrol (Gray) Communication failure (White) Status not yet confirmed (Background Gray) Alarm Off Un-confirmed alarm
- 25. 25 PST (Partial Stroke Test) SchedulerPST (Partial Stroke Test) SchedulerPST (Partial Stroke Test) SchedulerPST (Partial Stroke Test) Scheduler PST Scheduler works on the Asset Monitoring Softwareworks on the Asset Monitoring Softwareworks on the Asset Monitoring Softwareworks on the Asset Monitoring Software, and executes andexecutes andexecutes andexecutes and manages all the partial stroke test (PST) of the emergency shutdown valvesmanages all the partial stroke test (PST) of the emergency shutdown valvesmanages all the partial stroke test (PST) of the emergency shutdown valvesmanages all the partial stroke test (PST) of the emergency shutdown valves by partially operating them during the plant operation with intervals. PST enables to extend the interval of proof test that is to be conducted during the plant shutdown, and it reduces the losses caused by the plant shutdownit reduces the losses caused by the plant shutdownit reduces the losses caused by the plant shutdownit reduces the losses caused by the plant shutdown. The combination ofThe combination ofThe combination ofThe combination of ProSafeProSafeProSafeProSafe----RS, Asset Monitoring Software, and ESD valvesRS, Asset Monitoring Software, and ESD valvesRS, Asset Monitoring Software, and ESD valvesRS, Asset Monitoring Software, and ESD valves from various vendorsfrom various vendorsfrom various vendorsfrom various vendors is Asset management Software safety solution to support safe plant operations. PST Scheduler enables planning and execution of PST efficiently and safely to realize more efficient and safer plant operationsto realize more efficient and safer plant operationsto realize more efficient and safer plant operationsto realize more efficient and safer plant operations
- 26. 26 IntegratingIntegratingIntegratingIntegrating Asset Monitoring Software with AlarmAsset Monitoring Software with AlarmAsset Monitoring Software with AlarmAsset Monitoring Software with Alarm Management System:Management System:Management System:Management System: BenefitsBenefitsBenefitsBenefits Acquire and display the device diagnosis information Notify the alarms related to the field devices Manage the field device information Record the historical and maintenance messages Receive Real Time KPIs Receive Alerts View Production screens Issue orders, setpoints, etc. View Production reports Enables management by exception
- 27. 27 Thank you