Payback Profile:: Suncor Uses Bently Nevada To Increase Profitability - Part 2

CASE
HISTORY
PAY B A C K P R O F I L E :
Suncor Uses Bently Nevada to Increase Profitability Part 2

Using process data correlation to resolve a chronic vibration problem
Daniel Srinivasagam, P.Eng.

Staff Rotating Equipment Engineer Upgrading Maintenance & Engineering Suncor Energy, Inc, Oil Sands e-mail: [email protected]
Editors Note: Part 1 of this article appeared on page 44 in the First Quarter 2003 issue of ORBIT and chronicled some of the savings realized by Suncor during the five years since the system was first installed. Part 2 continues with another example of how the system has benefitted Suncor.
System Overview In 1998, Suncors Upgrading Operations combined forces with Bently Nevada to undertake a major Machinery Protection System project titled the Continuous Vibration Monitoring Project (CVMP). The first phase of the CVMP included the upgrade of ten pump/compressor trains with one 3300 Series monitoring system per train. Bently Nevada was the engineering contractor for this project and provided many services, such as system engineering, electrical design/labor/materials, mechanical design,
Mark Polukoshko, P.Eng.

Account Manager GE Energy Bently Nevada Product Line e-mail: [email protected]
About Suncor
Suncor Energy Inc. is a growing, integrated energy company, strategically focused on developing one of the worlds largest petroleum resource basins Canadas Athabasca oil sands. In the 37 years since history was made by tapping oil sands to produce the first commercial barrel of synthetic crude oil, Suncor has grown to four major business divisions and 4,000 employees. Near Fort McMurray in northern Alberta, Suncor recovers bitumen from oil sand and upgrades it to refinery-ready feedstock and diesel fuel. Suncor pioneered the worlds first commercially successful oil sands operation in 1967 and maintains a leading position in Canadas oil sands industry. In 2003, expanded mining and upgrading facilities contributed to record production of an average 216,600 barrels of oil per day. Construction is underway for the next phase of oil sands growth, which is expected to deliver production capacity of 260,000 barrels per day in 2005, growing in stages to a goal of up to 550,000 barrels per day by 2010 to 2012.
ORBIT
2Q04
CASE HISTORY
CHRONIC VIBRATION PROBLEM ON 7K10

HAD
PLAGUED THE MACHINE FOR SOME TIME
project management, documentation, and overall site supervision. Installation and commissioning of this complex operation required the coordination of many Bently Nevada departments, including Manufacturing, Project Engineering, Mechanical Engineering, Systems and Instrumentation, Machinery Management Services, System Integration Engineering, and Training. Phase one was completed in October 1998. Phase two of the CVMP was completed in May 1999 and included the installation of a Data Manager 2000 (DM2000) data acquisition, diagnostics, and trending system for a total of 18 machines. In addition to the vibration data available from the DM2000 system, process data is integrated from the plants process historian database (Honeywell PHD) via an OPC client/server link. This link allows operations and maintenance personnel to correlate process data with vibration information to better understand the health of their machinery. The DM2000 system is also connected to the corporate LAN allowing Suncor personnel to view the live machinery dynamic information from their office workstations. Figure 1 shows the system arrangement.
MACHINERY VIBRATION AND OTHER INFORMATION
PROCESS INFORMATION
CONTROL ROOM
PROCESS CONTROLLER TDXnet 3300 MONITORING SYSTEMS
NETWORK HUB HONEYWELL PROCESS CONTROL NETWORK PROCESS HISTORIAN DATABASE
DATA MANAGER 2000
NETWORK SWITCH
PROCESS CONTROL SYSTEM OPERATOR CONSOLE
BUSINESS NETWORK BRIDGE
SYSTEM ARRANGEMENT. | FIG. 1
2Q04
ORBIT
CASE HISTORY
A Recurring Vibration Problem on Compressor 7K10 Part 1 of this article described how Suncor used their Bently Nevada condition monitoring system (referred to as the CVMP by Suncor) to identify rotor damage on Kerosene Recycle Compressor 7K10 and resolve these problems without the need for an unplanned outage, saving in excess of $1 million CDN. However, the same compressor has also suffered from a
MONTH ACTIVITY
chronic vibration problem for the past few years. This article examines the problem and its resolution using information provided by the CVMP. The Cycle A chronic vibration problem on 7K10 had plagued the machine for some time. It typically followed a predictable sequence of events, lasting approximately 6 months, as follows:
The unit is put in service after an overhaul and/or seal/bearing work. Vibration amplitudes typically remain at very acceptable levels (less than 1 mil), well below alarm limits. 1X vibration amplitude in both X- and Y- planes of the compressor inboard bearing begins to gradually increase for 1 to 2 months, eventually reaching alarm limits. Unit is opened for inspection; hard, varnish-like depositions are sometimes found on seal components (Figure 2) that result in reduced clearances at the seals dual bushing.
1 4
4 6
VIBRATION BEGINS
VARNISH
TO GRADUALLY
DEPOSITION ON THE OUTER SEAL
INCREASE FOR
1 TO 2 MONTHS, EVENTUALLY REACHING
(DUAL) BUSHING. FIG. 2
ALARM LIMITS
ORBIT
2Q04
CASE HISTORY
Using DM2000 for a Closer Look In October 2003, the chronic problem described above resurfaced with vibration amplitudes at the compressor inboard bearing reaching ALERT and then eventually DANGER levels. Eager to find the root cause of this recurring problem, Suncor carried out a complete analysis using data collected by their DM2000 system. A significant aspect of Suncors installation was the integration of process data into their CVMP, allowing them to correlate mechanical health indicators (such as vibration and bearing temperatures) with process-related conditions. Upon investigation, Suncor identified an inverse correlation between the vibration amplitude at the compressors inboard bearing and the seal oil inlet temperature the lower the inlet temperatures, the higher the vibration amplitudes (Figure 3).
EAGER TO FIND THE
ROOT CAUSE OF THIS RECURRING PROBLEM, COMPLETE ANALYSIS USING DATA

COLLECTED BY THEIR DM2000 SYSTEM
SUNCOR CARRIED OUT A
TRENDS SHOWING INVERSE CORRELATION BETWEEN VIBRATION AMPLITUDE AND SEAL OIL INLET TEMPERATURE. ORANGE LINE SHOWS VIBRATION ALERT LEVEL; RED LINE SHOWS VIBRATION TRIP LEVEL. | FIG. 3
UPON INVESTIGATION, SUNCOR IDENTIFIED

AN
INVERSE CORRELATION BETWEEN THE VIBRATION AMPLITUDE AT THE SEAL OIL INLET TEMPERATURE
COMPRESSORS INBOARD BEARING AND THE
2Q04
ORBIT
CASE HISTORY
Root Cause As a temporary fix, the control system setpoint was changed to maintain the seal oil inlet temperature between 120 and 125 deg F instead of 105 to 115 deg F. This took place at approximately 9:00 AM on October 22, 2003, and, as shown in Figure 3, had an immediate effect on the overall vibration amplitude, dropping it below alarm levels and maintaining it between 2.5 and 3.2 mils. Over the next three months, with the new temperature setpoints established, the vibration amplitudes continued to decrease and stabilize, ranging between 1.5 and 2.2 mils as shown in Figure 4. During this time, Suncor was able to methodically investigate the root cause of the problem, which was ultimately identified as freeze-up or lack of freedom of the seal bushing, which had a direct effect on the dynamics of the rotor.
(continued on page 29)
THE
ROOT CAUSE WAS ULTIMATELY IDENTIFIED AS FREEZE-UP SEAL BUSHING
OR LACK OF FREEDOM OF THE
STABILIZED VIBRATION AMPLITUDES AS A RESULT OF TEMPERATURE SETPOINT CHANGES. | FIG. 4
TOTAL AVOIDED COSTS CAME TO $365,000 CDN; SUNCOR WAS ABLE TO KEEP THE MACHINE ONLINE AND
WITHIN ACCEPTABLE VIBRATION LEVELS WHILE A MORE
PERMANENT REMEDY WAS IDENTIFIED
ORBIT
2Q04
CASE HISTORY
Epilogue By virtue of a simple setpoint change to the seal oil inlet temperature, an unplanned unit shutdown with an estimated duration of 72 hours had been avoided. Total avoided costs came to $365,000 CDN ($300,000 in lost production and $65,000 in maintenance expenditures). Suncor was able to keep the machine online and within acceptable vibration levels while a more permanent remedy was identified. They are now developing a project to modify and upgrade the seal design, and also to overcome several existing limitations in the lube and seal oil systems. The correlation capabilities of DM2000 proved indispensable in diagnosing this particular problem.
They allowed Suncor to quickly identify the relationship between two independent parameters that might never have been noticed had they not integrated condition and process data into the same system. Once the correlation between the seal oil temperature and the vibration amplitude was established, the recommendation for a proposed solution followed through as a logical result. The solution was quick, effective, and allowed Suncor to continue operations while the permanent root cause was addressed. And, DM2000 helped Suncor narrow their root cause investigation to the sealing and lubrication components of the machine, saving time and money.
Summary As demonstrated in Parts 1 and 2 of this article, Suncors Upgrading Operations are using the DM2000 system to manage their critical rotating machinery more effectively, reducing both downtime and repair costs. Suncor is very pleased with both the system and Bently Nevadas turnkey project capabilities that were used to install the system for them back in 1999. Payback from the system has been so favorable that Suncor is currently looking towards further enhancements. Projects to include additional machinery from the newer areas of Upgrading under the CVMP are under consideration.

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CASE

Suncor Uses Bently Nevada to Increase Profitability Part 2

Daniel Srinivasagam, P.Eng.

Mark Polukoshko, P.Eng.

CHRONIC VIBRATION PROBLEM ON 7K10

PLAGUED THE MACHINE FOR SOME TIME

MACHINERY VIBRATION AND OTHER INFORMATION

PROCESS CONTROLLER TDXnet 3300 MONITORING SYSTEMS

NETWORK HUB HONEYWELL PROCESS CONTROL NETWORK PROCESS HISTORIAN DATABASE

DATA MANAGER 2000

PROCESS CONTROL SYSTEM OPERATOR CONSOLE

BUSINESS NETWORK BRIDGE

SYSTEM ARRANGEMENT. | FIG. 1

DEPOSITION ON THE OUTER SEAL

(DUAL) BUSHING. FIG. 2

ROOT CAUSE OF THIS RECURRING PROBLEM, COMPLETE ANALYSIS USING DATA

SUNCOR CARRIED OUT A

UPON INVESTIGATION, SUNCOR IDENTIFIED

COMPRESSORS INBOARD BEARING AND THE

ROOT CAUSE WAS ULTIMATELY IDENTIFIED AS FREEZE-UP SEAL BUSHING

OR LACK OF FREEDOM OF THE

STABILIZED VIBRATION AMPLITUDES AS A RESULT OF TEMPERATURE SETPOINT CHANGES. | FIG. 4

PERMANENT REMEDY WAS IDENTIFIED

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