COMPASS The world’s only and fully ‘ Integrated Machine Monitoring System’ Concepts and Applications Power Plants Oil & Gas Industry Heavy Process Industries Petrochemical Plants

File namePage 2 Presentation, Content & Structure Bruel & Kjaer Vibro (BKV) & Thomassen Compression Systems (TCS), together in Reciprocating Compressor Monitoring Purpose of Integrated Monitoring Function of Monitoring Systems –Safety Monitoring –Condition Monitoring System Configuration –Communication Links –Integration with DCS Benefits for: –Machine Vendors –End-Users –System Integrators (DCS, Contractors)

File namePage 3 Total Reciprocation Compressor Monitoring Machine Protection, Condition and Performance Monitoring Systems A Co-operation between Condition Monitoring Systems And

File namePage 4 Integrated Monitoring, all historic data available MechanicalProcessPerformance Shafts/Bearings Shaft vibration Shaft displacement Bearing wear debris Bearing temperature Stator/blades/casing Vibration Temperature Clearance Other Motor current Partial discharge Winding temperature Etc. Inlet/outlet temperature Inlet/outlet pressure Valve temperature Flow Speed Power Running hours Etc. Efficiency Head Pressure ratio Energy balance Etc.

File namePage 5 Monitoring Principle The BKV - TCS philosophy for “Integrated Machine Monitoring” Distinction between: Measuring –Measuring requires human interpretation of current measurements Monitoring –Monitoring is a completely automated comparison between the current and reference measurements

File namePage 6 System Overview

File namePage 7 System Concepts Reduce No. of components in LIM –only 4 different modules, programmable inputs –no 4-20 mA output, but Software link (Modbus) Reduce No. of LIMs –multiple machines in single LIM –high density of channels in one LIM, up to 112 channels for multiplexed I/O –smart Relays where multiple input signals can switch the Relay Reduce Network Load –event based data storage –analyzer in LIM, no need tot transfer time signals over network, –alarm generation in LIM –DTF File (simple ASCII Format) to transfer Process data from DCS to CCS Increase Reliability and Stability –Dual Power Supply –Relay (de)activation in LIM, no computer needed –Continuos self testing of LIM functionality

File namePage 8 Safety Monitoring Condition Monitoring Purpose of Condition Monitoring Goal: Detect potential machine problems in an early stage of development Action: Software warning in an early stage of development Maintenance strategy: Condition based Co-ordination with production Yes Purpose of Safety Monitoring Goal: To avoid dangerous situations for man, environment and machine Action: Trip just before moment of danger Maintenance strategy: ‘Run to almost break’ Co-ordination with production: No

File namePage 9 Prevent catastrophic damage But.. NO indication of machine condition NO warning NO post analysis NO remote access Result… Lost production Faults continue to occur Monitor machine condition Therefore… Early warning Fault analysis Machine condition is always known Result… Improved machine availability Prevent futher failures Safety Monitoring Condition Monitoring Time Vibration Machine stopped Danger Alarm level Vibration Time Lead time for repair Fault detected

File namePage 10 Condition Monitoring Techniques CPB spectrum FFT spectrum SED Cepstrum Rod Drop AMS, Adaptive Monitoring Strategy –Process classes in order to monitor under equal Process Condition Alarm on all Spectral Measurements, Real Monitoring instead of Measuring. Transient Monitoring No International Standards available Condition Monitoring

File namePage 11 Condition Monitoring, Alarm on Spectrum

File namePage 12 Condition Monitoring Systems - Drawback comments Nice pictures, but only experienced experts can analyse vibration data Machine vibration changes with operating conditions Need to be on site to work with system Long term data storage is inpractical

File namePage 13 Monitoring at a glance COMPASS uses alarm traffic lights to give users an instantaneous overview of machine condition. RED - DANGER STATE YELLOW - ALERT STATE GREEN - NORMAL STATE BLUE - SYSTEM ALARM RED - DANGER STATE YELLOW - ALERT STATE GREEN - NORMAL STATE BLUE - SYSTEM ALARM

File namePage 14 Monitoring at a Glance

File namePage 15 Change of Operating Condition? Overlay Plots answer

File namePage 16 Remote Access via the Internet

File namePage 17 Data Storage Based on Events instead of Time

File namePage 18 COMPASS, Automatic Alarms on Result

File namePage 19 Reciprocating Compressors, 2 point Rod Drop

File namePage 20 Built-in smoothing techniques

File namePage 21 Reciprocating Compressors, Relative Deviation Result

File namePage 22 Reciprocating Compressor Performance

File namePage 23 Reciprocating Compressor Performance

File namePage 24 Reciprocating Compressor Performance

File namePage 25 Why BKV - TCS? Implementing COMPASS means: –Implementing a proven system which Integrates Safety, Condition and Performance Monitoring –Implementing a System with full backup of machine vendor (Thomassen Compression Systems) –A system built for reliable trending and predictive maintenance –The use of unique and advanced condition monitoring techniques –The use of unique and advanced Performance Monitoring techniques –Project Implementing a system conform ISO 9001 standards References General: –Statoil Norway –Kollsnes Norway –PDO Upstream facilities Oman –Oman LNG –Woodside LNG Australia –Nigeria LNG –Hoekloos Netherlands References Recip Compressor: –Bulwer Island –Woodside LNG –NAM (5 plants)

File namePage 26 Investing in Integrated Monitoring Systems! The question is not: ‘Can I afford to invest in an Integrated Monitoring System?’ but: ‘Can I afford not to invest in an Integrated Monitoring System?’ Being better then the rest