DZ2011 Natural Gas-Pipelines Caterpillar Krenek

8/13/2019 DZ2011 Natural Gas-Pipelines Caterpillar Krenek

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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



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PI Sto SEPI

Idento obwarnpend



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PI A PI P

PI D PI W PI S PI A PI N



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PI A PI W

PI A PI N



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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

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0

10

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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

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0

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0

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750

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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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DZ2011 Natural Gas-Pipelines Caterpillar Krenek