Using the PI System for Proactive Asset...

Presented by

Using the PI System

for Proactive Asset

Management

Caterpillar’s Solution

David Krenek

Market Professional

© Copyr i gh t 2012 OSIso f t , LLC.

Topics

• Proactive Asset Management Background

• Caterpillar Solution

• Examples of Technology in Use

• Benefits

2


Proactive Asset Management (aka Condition Monitoring)

3

Failure Unhealthy Healthy

32 psi

30 psi

$$$$ $$ $

No Flexibility Some Flexibility Most Flexibility


Condition Monitoring

4

Resources

Operational Strategies

Maintenance Strategies

Equipment

Performance

Condition

Scheduled

Corrective

Action


Power for Natural Gas Compression

5

Natural Gas Compressor Station

• 4 X G3612 Engines

• 14,200 hp

• $2.00 / MCF

• $185,000 / day

• 1 hr downtime = $1,930


Why the Pi System

• Proof of Concept Identified Gaps – Aggregate Data from Various Industrial Controls

– Visualization to Facilitate Root Cause Determination

– Data Archiving for “cradle-to-grave” Analysis

– Additional Analytics

– Platform for Information Distribution

• Core Competency – Manufacturing Highly Durable and Reliable Machines

– Not Data Management Software

• Time and Cost to Market

• Common Platform to Customers Using the PI System

6


Key Processes

Data Types

• Analog

• Derived

• States

• Faults

• Once per Second

• PI Interfaces

• Cat & non-Cat Products

Aggregating Data

7


Key Processes

Transmitting Data

8


Connectivity Flexibility

• Cell

• DSL

• Customer Network

• PI-to-PI Interface

• Other Historian to PI System

9


Key Processes

10


Key Processes

11

GE SmartSignal EpiCenter

• Non-parametric, multivariate data analysis


Engine Speed

Load Factor

30-Jan-12 00:00:0022-Jan-12 00:00:00 8.00 days

820

840

860

880

900

920

940

960

980

1000

1020 Static Setpoint

Dynamic Setpoint

Dynamic Setpoint Cyl #11 Port Temp

Engine Speed

Engine Load Factor

12


Key Processes

13


PI AF • Security

• Network

• Data

• Scalability

14


Component History & KPI’s

15

0.0

%

0.1

%

0.1

%

0.0

%

0.1

%

74

.2%

25

.5%

0 -

75

0

75

0 -

80

0

80

0 -

85

0

85

0 -

90

0

90

0 -

95

0

95

0 -

10

00

10

00

-1

05

0

Speed

Speed Histogram

1.0

%

0.0

%

0.0

%

0.0

%

0.0

%

0.0

%

0.0

%

0.0

%

0.2

%

19

.6%

59

.9%

19

.0%

0.1

%

0 -

50

50

-5

5

55

-6

0

60

-6

5

65

-7

0

70

-7

5

75

-8

0

80

-8

5

85

-9

0

90

-9

5

95

-1

00

10

0 -

10

5

10

5 -

11

0

Percent Rated Torque

Torque Histogram


The Value of High Fidelity Data

Are these trends from

different processes?

-6

-4

-2

0

2

4

6

0 500 1000 1500 2000 2500 3000 3500 4000

-6

-4

-2

0

2

4

6

0 500 1000 1500 2000 2500 3000 3500 4000

-6

-4

-2

0

2

4

6

0 500 1000 1500 2000 2500 3000 3500 4000

-6

-4

-2

0

2

4

6

0 500 1000 1500 2000 2500 3000 3500 4000

-6

-4

-2

0

2

4

6

0 500 1000 1500 2000 2500 3000 3500 4000

-6

-4

-2

0

2

4

6

0 500 1000 1500 2000 2500 3000 3500 4000

Maybe Not!

Maybe

16


Events & Diagnostics Timestamp Code Description

27-Nov-11 21:11:07 1045-1 Low Intake Manifold Pressure

27-Nov-11 21:11:22 242-1 Engine Overload

27-Nov-11 21:12:02 411-1 Cylinder #11 Detonation

High Fidelity Data

999.7

61.619

7

0

22.532

22.621

47.113

Engine Speed

Engine Load Factor

Compressor load step

Engine ECM Active Event CID Number 01

Desired Air Manifold Pressure

Actual Air Manifold Pressure

Wastegate Position Command

27-Nov-11 21:14:0027-Nov-11 21:04:00 10.00 minutes

Sample

0

200

400

600

800

1000

1200

0

120

0

10

0

2000

0

40

0

40

0

120

17


1001

58.463

6

0

21.691

21.716

48.469

Engine Speed

Engine Load Factor


Engine ECM Active Event CID Number 01

Desired Air Manifold Pressure

Actual Air Manifold Pressure

Wastegate Position Command

27-Nov-11 21:13:0027-Nov-11 21:10:00 3.00 minutes

Sample

0

200

400

600

800

1000

1200

0

120

0

10

0

2000

0

40

0

40

0

120

• Event begins and ends in 3 minutes!

Desired Air Pressure (Red)

is greater than Actual (White)

Engine Commands

Wastegate (Blue) to close

Air Pressure Not Increasing

Command Now Full Closed

Low Pressure Alarm Active

Increasing Air Pressure

Indicates Wastegate has

Closed

Engine Indicated Load Peaks

(Cyan) and Overload Fires

Wastegate did not

close upon engine

command.

Recommendation:

Inspect/Repair

Wastegate Bushings

Linkage or

Actuator

at next scheduled

Shutdown

High Fidelity Data

18


Data Enhancement Combustion Time vs. Misfire

19

Cylinder 01 Unfiltered Combustion Time

11-Sep-12 00:00:0028-Aug-12 00:00:00 14.00 days

0

2

4

6

8

10

12

15

Cylinder 01 Misfire

11-Sep-12 00:00:0028-Aug-12 00:00:00 14.00 days

0

10

20

30

40

50

60

Combustion Time

• Poor Visualization

Misfire Rate

• Insightful

• 12,000 points/day

• 12 Cylinder Engine

• 1 sec sample rate

• 1,036,800 points/day


Pre-Chamber Check Valve

Engine Speed

Cylinder 10 Misfire

26-Jul-12 00:00:0023-Jul-12 00:00:00 3.00 days

Transformer & Misfire - Cyl inder 10

0

400

600

800

1200

0

60

Cyl #10 Combustion Time

20


Benefits

21

• Case Study

– 2 X G3612 Engine Driven Compressors

– Pipeline Transmission

– Manned 5 days / week – 8 hours day

– 14 months of service

– 99.5% Reliability

– 488 Hours Meantime Between Outage

– 2 Callouts in Past 6 Months


Current Implementation

22


Brought to you by

David Krenek Market Professional

Petroleum Group

Caterpillar, Inc.

13105 Northwest Freeway

Suite 1010

Houston, Texas 77040-6321

713-329-2221

Email: [email protected]

www.catoilandgasinfo.com

mailto:[email protected]


Further Reading

• “Utilizing Equipment Data for Proactive Asset Management”

• Atmos Energy & Caterpillar

• 2012 Gas Machinery Conference

24

www.catoilandgasinfo.com


Spark Plug Failure • Analytics alerted that Secondary Transformer Voltage had dropped (blue)

• Drill down into data identified short periods of misfire (yellow)

• To reduce risk of callout during 4-day weekend, Operator replaced spark plug on afternoon

of day before weekend

25

Engine Speed

Cyl inder 02 Transformer Secondary Output Voltage Percentage

Cyl inder 02 Misfire

23-Nov-11 16:00:0023-Nov-11 06:00:00 10.00 hours

Transformer & Misfire - Cyl inder 2

0

400

600

800

1200

0

120

0

60

Misfire

Low Secondary Voltage

Normal Secondary Voltage


Engine Lube Oil Filter

26

Oil Filter ΔP

Oil Press

Oil Temp

Oil-Coolant ΔT

Filter Changed

Oil Filter Differential Pressure

Incident Reported

116 Days


Data Enhancement • Noisy Signal

will delay

persistence

condition for

EPI-center

27

2.5802

Oil Filter Differential Pressure

18-Apr-12 00:00:0001-Oct-11 00:00:00 200.00 days

Plot-0

-5

-1

1

3

5

7

10

4.4224

10 minute Average Oil Filter Differential Pressure

18-Apr-12 00:00:0001-Oct-11 00:00:00 200.00 days

Plot-0

-5

-1

1

3

5

7

10

4.4224

2.5802

10 minute Average Oil Filter Differential Pressure Oil Filter Differential Pressure

18-Apr-12 00:00:0001-Oct-11 00:00:00 200.00 days

Plot-0

-5

-1

1

3

5

7

10

• Filtered Signal

Improves

visualization

and analysis


Pre-Chamber Port Erosion

Blue is measured

Green is estimated

28


Sensor Failure

08-Apr-10 12:15:0008-Apr-10 04:15:00 8.00 hours

Plot-0

-50

50

150

250

350

450

550

650

750

-50

750

0

5

08-Apr-10 11:44:21

568.99

461.12

1491-4

Turbine Inlet Temp with High Temp Spike

Turbine Outlet Temperature – Normal Reading

Intermittent, Short Duration Diagnostic Code - 1491

29


1.71

2.04392

2.05578

2.01599

3

Process gas Compression ratio at point A for 1st stage

Enhanced Temp Ratio Cylinder #1 Initial




11-Apr-12 00:00:0014-Mar-12 00:00:00 28.00 days

Compressor Discharge Temperatures

1.2

1.4

1.6

1.8

2

2.2

1

3

1

3

1

3

0

10 1.71

2.05064

2.04638

2.02484

3

Process gas Compression ratio at point A for 1st stage

Enhanced Temp Ratio - Cylinder #1




11-Apr-12 00:00:0014-Mar-12 00:00:00 28.00 days

Compressor Discharge Temperatures

1.2

1.4

1.6

1.8

2

2.2

1

3

1

3

1

3

0

10

Signal Processing

• Temperature ratio is a function of Pressure Ratio

• Using Temperature Ratio Function Reduces Model Maintenance and

Improves Visualization.

30

Cylinder #1 Suction Valve Repaired

Cylinder #3 Discharge Valve Repaired

Cylinder #5 DischargeValve Repaired

Using the PI System for Proactive Asset...

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