improving reliability with caterpillar condition monitoring services

1 © Copyright 2011 OSIsoft, LLC.

Presented by

Improving Reliability with Caterpillar Condition Monitoring Services

David Krenek

Equipment Management Professional

Caterpillar, Inc. - Global Petroleum


Topics

• About Caterpillar Global Petroleum

• Background – Why Condition Monitoring

• Overview of the Caterpillar Solution

• How the PI System Fits into the Solution


Products – Global Petroleum

• Natural Gas Engines 95 to 8180 bhp

• Diesel Engines 40 to 21,760 bhp

• Generator Packages

• Well Service Packages


Global Petroleum Applications Served

• Gas Compression

• Drilling

• Well Servicing

• Production


Condition Monitoring Service Opportunity

• Pressure to increase productivity

• Equipment is more complex

• More data available

• Limited Information for Decision Making

• Changing workforce

• Assets are

– Dispersed

– Low Population Density

– Autonomous

• Experts are

– Valuable

– Not next to equipment


Bathtub Curve Quality

Reliability

Durability

Wear out

Infant Mortality

Useful Life


Reliability & Condition Monitoring • Caterpillar - “A proactive analysis

process using equipment & application data from multiple sources to make informed application, maintenance, repair, or component replacement decisions.”

• Elements

– Electronic Data

– Fluid Analysis

– Inspections

– Component Life Cycle Position

– Site Conditions

• General Sense (Military) - "The probability that an item will perform a required function without failure under stated conditions for a stated period of time.“

• Business Sense (Barringer) – Includes long term costs

– Procurement

– Installation

– Operations

– Maintenance


Solution Requirements

• Aggregate from Cat & non-Cat equipment

• Transport data offsite

• Analyze data automatically 24/7 to find exceptions for early warning

• High fidelity data to capture fast acting & intermittent events

• Distribute exceptions to experts

• Provide drill down

• Distribute recommendations and asset performance to stakeholders

• Maintain Knowledge Base


Service Solution Using the PI System


• PI Modbus Interface

• PI OPC Interface

Solution Using the PI System


• Cell to Caterpillar PI Server

• DSL to Caterpillar PI Server

• PI to PI Interface

• Other Historian to PI Server



• PI SDK – PI Server to SmartSignal EPI Center

• Identify exceptions to obtain early warning of pending failures



• PI AF

• PI ProcessBook

• PI DataLink

• PI WebParts

• PI SMT

• PI ACE

• PI Notifications



• PI AF

• PI WebParts

• PI ACE

• PI Notifications



Solution – Early Warning of Developing Failures

Filtered Combustion Time – Cylinder #1

6 months

• Recommended Action – Visually inspect cylinder head at next out of service PM.

• Found eroded pre-chamber

• Avoided Potential Piston/Liner and Turbocharger Failure


0.27715

0.00391

-0.05559

-0.06043

0.01560

-0.08348

-0.2

0.2

26-M ar-11 00:00:0019-M ar-11 00:00:00 7.00 days

Customer Unit

-1

-0.8

-0.6

-0.4

-0.2

0

0.2

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0.8

1

Solution – Drill Down – PI WebParts

Combustion Time Deviation – G3606

• Used to assess incidents reported by EPI Center

• Where is engine relative to expected performance?

+1 msec

-1 msec


1000.3

568.99

460.87

0

0

08-Apr-10 12:00:0008-Apr-10 04:35:00 7.42 hours

Customer Unit

0

200

400

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1200

-50

750

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750

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Solution – ECM Event & Diagnostics – PI WebParts

• Used to detect short duration, intermittent events prior to failure

• Link diagnostics to observed behaviors to identify mode.

Start Duration (Minutes) Descripton

08-Apr-10 02:17:24 3.3 Right Turbo Turbine Inlet Temperature Sensor : Voltage Above Normal





Engine Speed

Turbine Inlet Temp

Turbine Outlet Temp

Diagnostic Active


19-M ar-11 13:00:0018-M ar-11 13:00:00 24.00 hours

Plot-0

Solution – High Fidelity Capability

• High fidelity data for most of operation.

• But low fidelity could miss important events.

Engine Speed

What Happened Here?

Port Temperatures – 12 Cylinders

Filtered Combustion Times – 12 Cylinders


19-M ar-11 12:13:4519-M ar-11 12:12:45 60.00 seconds

Plot-0

750

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75

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0

20


• UCP automatically loads compressor up to next load step

• Engine speed droops.

• Indicated load increases

• UCP unloads compressor after 5 seconds

• Engine is stopped after 7 seconds.

Engine Speed

Indicated Load %

Compressor Load Step


591.07

0.0000

0

0

8

0

7

1

10

10

0

6

0

10

1

0

0

3.0500

10.988

0.0000

27.856

37.353

2.9520

19-Mar-11 12:13:4019-Mar-11 12:13:30 10.00 seconds

Plot-0

750

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120

19-Mar-11 12:13:39.33

1042.6

0

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1

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10

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0

9.2803

33.433

0.0000

8.9819


• Governor racks fuel

• Wastegate closes to maintain air/fuel ratio.

• Turbo lag causes mixture to go rich.

• Multiple cylinders detonate

A/F Ratio White = Desired Black = Actual

Fuel Command

Wastegate Command %


UNIT1_CYL01_4HRM ISFIRE.Value

0


0


0.05979



0


2.02369

UNIT1_CYL01_EXH_PORT_TMP.Value

550.327


540.215


546.991


540.664


556.534


530.699

29-Jul-10 15:00:0022-Jul-10 15:00:00 7.00 days

Unit 1

0

0.5

1

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0

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Solution – High Fidelity Capability – Tracking Misfire

• Increasing Misfire Possible Causes

• Excessive Spark Plug Gap

• Fouled Spark Plug

• Fouled Needle Valve

• Fouled PC Check Valve

• Detect before cylinder goes cold

Exhaust Port Temperatures

% Misfire


4.7410

26-M ar-11 20:40:0026-M ar-11 19:40:00 60.00 minutes

Unfiltered CT

0

2

4

6

8

10

12

14

15

Solution – Tag Tuning – Before & After

• Unfiltered Combustion Time

• Interested only in misfires

• 1 second updates = 1 million data points per day for 12 cylinder engine.

• Tag tuning reduces to 10 to 20k per day.


Condition Monitoring Benefit

Revenue Impact

• G3616 Gathering Compressor

– 32 MMSCFD @ $4.00/MSCFD

– Increase Utilization by 0.1 point = $47,000 / yr

– 8.75 Hours

Cost Impact

• Failed pre-chamber

– Replace piston & liner $25 to $35K

– Replace turbocharger $50 to $75K


Questions David Krenek

Market Professional

Marine & Petroleum Power Division - Petroleum Group

Caterpillar, Inc.

13105 Northwest Freeway, Suite 1010

Houston, Texas 77040-6321

713-329-2221

Email: [email protected]

www.cat.com

mailto:[email protected]

improving reliability with caterpillar condition monitoring services

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