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Presented by
Improving Reliability with Caterpill
Condition Monitoring ServicesDavid KrenekEquipment Management Professional
Caterpillar, Inc. - Global Petroleum
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Topics About Caterpillar Global Petroleum Background Why Condition Monitoring Overview of the Caterpillar Solution
How the PI System Fits into the Solution
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Products Global Petroleum
Natural Gas Engines95 to 8180 bhp Diesel Engines
40 to 21,760 bhp Generator Packages Well Service Packages
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Global PetroleumApplications Serve
Gas Compres Drilling Well Servicin Production
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Condition Monitoring Service Opportun
Pressure to increaseproductivity
Equipment is more complex More data available
Limited Information forDecision Making Changing workforce
Assets are Dispersed Low Population Autonomous
Experts are Valuable Not next to equip
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Bathtub CurveQuality
Reliability
Wear out
Infant Mortality
Useful Life
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Reliability & Condition Monitorin Caterpillar - A proactiv
process using equipment
application data from musources to make informeapplication, maintenancecomponent replacement de
Elements Electronic Data Fluid Analysis Inspections Component Life Cycle Site Conditions
General Sense (Military) - "Theprobability that an item will perform
a required function without failureunder stated conditions for a statedperiod of time.
Business Sense (Barringer) Includeslong term costs
Procurement Installation Operations Maintenance
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Solution Requirements Aggregate from Cat & non-Cat
equipment Transport data offsite Analyze data automatically 24/7
to find exceptions for earlywarning
High fidelity data to capture fastacting & intermittent events
Distribute exceptions to Provide drill down Distribute recommenda
asset performance tostakeholders
Maintain Knowledge Ba
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Service Solution Using the PI System
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PIIn
PIIn
Solution Using the PI System
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CellPI S
DSLPI S PI to Othe
PI S
Solution Using the PI System
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PI Sto SEPI
Idento obwarnpend
Solution Using the PI System
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PI A PI P
PI D PI W PI S PI A PI N
Solution Using the PI System
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PI A PI W
PI A PI N
Solution Using the PI System
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Solution Early Warning of Developing Failur
Filtered Combustion Time Cylinder #1
6 months Recommended Action Visually inspect cylinder head at next out of service Found eroded pre-chamber Avoided Potential Piston/Liner and Turbocharger Failure
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0.277150.00391-0.05559-0.060430.01560
-0.08348-0.20.2
26-Mar-11 00:00:0019-Mar-11 00:00:00 7.00 days
Customer Uni
-1
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
1
Solution Drill Down PI WebParts
Combustion Time Deviation G3606
Usinc
repEP
Whrelexpper
+1 msec
-1 msec
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1000.3568.99460.8700
08-Apr-10 12:00:0008-Apr-10 04:35:00 7.42 hours
Customer Unit
0
200
400
600
800
1000
1200
-50
750
-50
750
0
2000
0
2000
Solution ECM Event & Diagnostics PI WebParts Us
sho
intevefai
Linobsbehide
Start Duration (Minutes) Descripton08-Apr-10 02:17:24 3.3 Right Turbo Turbine Inlet Temperature Sensor : Voltage Above Normal08-Apr-10 02:46:34 3.7 Right Turbo Turbine Inlet Temperature Sensor : Voltage Above Normal08-Apr-10 04:20:24 0.8 Right Turbo Turbine Inlet Temperature Sensor : Voltage Above Normal08-Apr-10 07:57:24 0.8 Right Turbo Turbine Inlet Temperature Sensor : Voltage Above Normal08-Apr-10 07:59:54 0.3 Right Turbo Turbine Inlet Temperature Sensor : Voltage Above Normal
Engine Speed
Turbine Inlet Temp
Turbine Outlet Temp
Diagnostic Active
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19-Mar-11 13:00:0018-Mar-11 13:00:00 24.00 hours
Plot-0
Solution High Fidelity Capability Hig
for
ope Bu
couim
Engine Speed
What Happened Here?
Port Temperatures 12 Cylinders
Filtered Combustion Times 12 Cylinders
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19-Mar-11 12:13:4519-Mar-11 12:12:45 60.00 seconds
Plot-0
750
800
850
900
950
1000
1050
1100
75
110
0
20
Solution High Fidelity Capability UC
loato n
Engdro
Indinc
UCcomsec
Engafte
Engine Speed
Indicated Load %
Compressor Load Step
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591.070.0000008071101006010100
3.050010.9880.000027.85637.3532.9520
19-Mar-11 12:13:4019-Mar-11 12:13:30 10.00 seconds
Plot-0
750
800
850
900
950
1000
1050
1100
0
20
0
10
0
10
0
10
0
10
0
10
0
10
0
10
0
10
0
10
0
10
0
10
0
10
0
2000
0
2000
0
30
0
120
0
30
0
120
19-Mar-11 12:13:39.33
1042.60080711010060101009.280333.4330.0000
8.9819
Solution High Fidelity Capability Go Wa
marati Tur
mix Mu
det
A/F RatioWhite = DesiredBlack = Actual
Fuel Command
Wastegate Command %
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29-Jul-10 15:00:0022-Jul-10 15:00:00 7.00 days
Unit 1
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0
5
0
5
0
5
0
5
0
750
0
750
0
750
0
750
0
750
0
750
Solution High Fidelity Capability Tracking Misf Increasing
Causes
ExceGap Foule Foule Foule
Detect bef
goes cold
Exhaust Port Temperatures
% Misfire
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4.7410
26-Mar-11 20:40:0026-Mar-11 19:40:00 60.00 minutes
Unfiltered CT
0
2
4
6
8
10
12
14
15
Solution Tag Tuning Before & After Un
Co
Intemis 1 se
1 mpercyl
Tagto 1
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Condition Monitoring BenefitRevenue 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-chamb
Replace piston &$25 to $35K
Replace turboch$50 to $75K
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QuestionsDavid KrenekMarket ProfessionalMarine & Petroleum Power Division - Petroleum GroupCaterpillar, Inc.13105 Northwest Freeway, Suite 1010Houston, Texas 77040-6321713-329-2221
Email: [email protected]
www.cat.com
mailto:[email protected]:[email protected] -
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