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
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Proactive Asset Management (aka Condition Monitoring)
3
Failure Unhealthy Healthy
32 psi
30 psi
$$$$ $$ $
No Flexibility Some Flexibility Most Flexibility
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Condition Monitoring
4
Resources
Operational Strategies
Maintenance Strategies
Equipment
Performance
Condition
Scheduled
Corrective
Action
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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
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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
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Key Processes
Data Types
• Analog
• Derived
• States
• Faults
• Once per Second
• PI Interfaces
• Cat & non-Cat Products
Aggregating Data
7
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Key Processes
Transmitting Data
8
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Connectivity Flexibility
• Cell
• DSL
• Customer Network
• PI-to-PI Interface
• Other Historian to PI System
9
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Key Processes
10
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Key Processes
11
GE SmartSignal EpiCenter
• Non-parametric, multivariate data analysis
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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
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Key Processes
13
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PI AF • Security
• Network
• Data
• Scalability
14
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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
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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
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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
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1001
58.463
6
0
21.691
21.716
48.469
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 21:13:0027-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
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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
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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
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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
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Current Implementation
22
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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
© Copyr i gh t 2012 OSIso f t , LLC.
Further Reading
• “Utilizing Equipment Data for Proactive Asset Management”
• Atmos Energy & Caterpillar
• 2012 Gas Machinery Conference
24
www.catoilandgasinfo.com
© Copyr i gh t 2012 OSIso f t , LLC.
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
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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
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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
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Pre-Chamber Port Erosion
Blue is measured
Green is estimated
28
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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
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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
Enhanced Temp Ratio Cylinder #3 Initial
Enhanced Temp Ratio Cylinder #5 Initial
Compressor load step
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
Enhanced Temp Ratio - Cylinder #3
Enhanced Temp Ratio - Cylinder #5
Compressor load step
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