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Oil industry: a pump survey for a pilot

Pumps move hot oil, water and fuel across a processing site. A site walk-through decided what PRECOG should measure on each group and where the pilot should start.

The surveyPump groupsOrder of the pilotMaintenance messages

Oil industry

The survey

The project started with a walk-through of the site. For each pump group the team recorded the equipment, the operating conditions, the existing measurements and the fixing options for the sensors. Parts of the site are classified as areas with explosive atmospheres (zone 1 and zone 2). Sensors and the mounting there must have a suitable rating.

The site has its own vibration meter. Its readings serve as a reference on site, so the values of the PRECOG sensors can be compared with them.

Equipment

Pump groups

Hot oil pump

A motor of about 132 kW in a very hot environment. Vibration trends show early bearing, shaft and mechanical wear, and also patterns that raise the risk of fire.

Compressor cooling water pump

Circulates the cooling water of a compressor. Vibration monitoring shows bearing wear, imbalance and abnormal mechanical behaviour.

Soft water pumps

Two pumps from Grundfos, type CR 45, about 45 m³/h, controlled by a frequency converter. Pressure and water consumption are the relevant data, next to vibration and the operating pattern.

Formation water pump

A KSB pump, type HGC, about 350 t/h at an operating temperature of 60 to 70 °C, in continuous operation. A leak at the gland is a known problem. The overhaul cycle is about 40,000 operating hours.

Fire water pumps

A critical safety system. The pumps start when the pressure has to be kept, controlled by a frequency converter. The start frequency and the pressure cycles show leaks.

Main collector gas oil pumps

KSB pumps, type CPK-S2, with a head of about 70 m. Vibration and temperature data already exist and are watched on a local monitor.

Pilot

Order of the pilot

  1. Main collector gas oil pumps. The existing vibration and temperature data are connected to PRECOG, so no new sensor is needed at first. PRECOG follows the trends and predicts bearing wear, friction, overheating and fire risk patterns. The maintenance staff get messages in plain words and do not have to watch a separate monitor.
  2. Fire water pumps. A vibration sensor follows the pump and the motor. PRECOG analyses the pressure maintenance, the start frequency, the duration of the pressure cycles and the pressure loss patterns. It learns the normal water withdrawal, for example for filling tanks, so that it does not raise a false alert for it.
  3. Formation water pumps. Two vibration sensors follow the bearings at the two ends of the pump, and a leak sensor follows the gland. PRECOG evaluates the vibration and the leak events together. The sensors need a rating for the explosive atmosphere.
Why this order. The first group already has data, so the pilot can start quickly. The fire water system is a critical safety system. The formation water pumps run continuously at high pressure and have a known leak problem.

Output

Maintenance messages

PRECOG sends short messages to the maintenance staff. Examples of what they can read:

  • The vibration trend of the main collector gas oil pump differs from the usual. Bearing wear or a friction problem is likely.
  • The temperature trend shows a heating pattern that raises the fire risk.
  • The pressure maintenance cycles of the fire water system have become more frequent. A leak is suspected.
  • The pressure loss differs from the normal water withdrawal pattern.
  • The bearing vibration of the formation water pump shows a growing deviation.
  • The condition of the machine differs from its usual operating behaviour. A check is recommended.