Critical Equipment Management Workshop

Kenneth St Brice

Critical Equipment Management Workshop

Overview of Rashpetco Operations

Rashpetco - Asset Overview

Daily Production• Gas - 2 BCFD• Condensate – 4500 BPD• Aqueous – 14,000 BPD

Organisation Overview - Condition Monitoring Set Up

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Maintenance Gen Manager

Instrument AGM

District Field Gen. Mgr

Technical Gen. Mgr

Production Gen Manager

Turbomachinery AGM

Planning AGM Electrical AGM

Inspection Gen Manager

- Site Operations

Operations Manager

Condition Monitoring

Asset Critical Equipment Infrastructure

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Number of Critical Rotating Equipment

ROSETTA

6 Gas Turbines

4 Generators

2 Compressors

WEST DELTA DEEP MARINE

13 Gas Turbines *

6 Generators *

7 Compressors *

1 Reciprocating Gas Compressor

* Phase VII Equipment yet to be commissioned.

Asset Infrastructure Overview

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• What Equipment Monitoring Systems Are Used Today?

– No Historian – No Remote Monitoring

◦ For Siemens SGT 400 Booster OEM Compressors - local monitoring performed using BN 3500 data

– Specialist systems◦ Vibration Monitoring – Rockwell ENPAC / EMONITOR◦ Lube Oil Monitoring◦ Electrical Infrared Monitoring◦ Bently Nevada System I planned for Phase VII◦ System I planned for extension across plant

History

• July 2009 – Fire on Heating Medium Pump @ CCR MEG Recovery Plant (Contract Plant)

• RCA pointed to bearing failure, seal failure, hot oil leak and fire as the sequel to the event.

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Analysis performedVibration and Spike Energy Assessment

Conclusion and ResolutionBy successful intervention the CM Team:• Avoided a repeat heating medium fire

incident on plant• Saved significant cost due to escalation

failures on seal, shaft, housing etc.• Built significant credibility shortly after

commencement of work as a team.

Success Story at Site

Event

• Condition Monitoring Team set up – March 2010

• In May 2010 – Carried out routine monitoring of WDDM Heating Medium Pump.

• Ascertained that bearing was in pending failure

• Recommended bearing change

Spall on bearing inner race

Current Problem Being Experienced

WDDM Booster Compressor - High Vibration• Booster Compressor trains have shown high and erratic

vibration patterns from installation. • The Gas Generator inlet end bearing been showing high

vibrations for the last 6 months. The vibration has been predominantly on the B machine but recently we have seen increases also on the A Gas Generator.

• The impact of the higher vibration has been to limit the machine speed which impacts deliverability.

• The OEM has changed out the Train B engine during a recent shutdown to carry out further diagnosis at their workshop.

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GG Inlet Bearing – 20th May 2010 GG Inlet Bearing – 20th May 2010

GG Inlet Bearing – 27th Oct 2010 GG Inlet Bearing – 27th Oct 2010

Current Problem Being Experienced