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SAVE were invited to perform a large vibration survey on the MV25 FPSO to investigate the source of high vibration on the Deck frames, AVM’s and the rotors of the GE LM2500 GG and PT, and Brush Alternators of all four newly commissioned Power Generator Packages.
The investigation results indicated that the deck frames were insufficiently stiff, although this was not the cause of the high vibration because a resonance is a response to an excitation force. The low stiffness was only influential during the transient run up when the rotor 1st critical speed was coincident with the deck frame resonance. On two of the generators, the vibration amplitudes at 1st Critical shaft speed exceeded the trip set point and shut the machine down. The PT’s which could operate at full speed had very high vibration amplitudes on the AVM’s, Deck Frame and GG/PT/ALT rotors.
Analysis of the AVM manufacturers data and measured vibration results, it was established that the AVM’s were efficient; however, they were insufficiently supported by the Deck frame. Analysis of the rotor dynamics and vibration data identified the probable source of the vibration to be the coupling assembly. A full RCA was initiated and SAVE provided independent expert advice and supporting evidence to the client throughout the process. An action from the RCA was to perform a mechanical inspection of the coupling assembly. During the inspection the insulated coupling spacer bolts were found to be loose. Further inspection also revealed that the insulated spacer rings had catastrophically failed.
After the insulated coupling spacers had been replaced and rotor alignment checks were complete, SAVE carried out an SAT test to confirm the vibration levels were acceptable and conformed to ISO 10816. A continuation to the RCA was implemented to identify the cause of the failed component.
SAVE have been assigned to performing an acoustic assessment of the Production Deck noise levels on the Buzzard Platform following the removal of acoustic pipe insulation. The assessment was performed to ascertain whether the removal of the acoustic lagging has had an adverse effect on the Production Deck areas or an adverse effect on the noise exposure levels of personnel working in the Production Deck areas. This is a long term project.
Measured noise levels were compared with previous area noise levels and calculation of the Daily Personal Noise Exposure Levels (LEP,d) were performed to assess their compliance with specified Lower and Upper Exposure Action values (LAV and UAV), and to specified Upper Exposure Limit (UEL). SAVE are responsible for updating the Area noise levels and Exposure levels of personnel in the Noise Exposure Management System (NEMS).
Routine onshore and offshore condition monitoring and Reliability Engineering services to CNOOC (Nexen) and Premier Oils on behalf of OPEX Group.
Our main roles and responsibilities are very similar to those detailed above, except that we provided routine support as a senior CM and RE consultant at both our clients offices and at our Client’s client’s offices and offshore assets. We are in regular contact with all OPEX Staff and also with CNOOC (Nexen) and Premier Oils personnel.
We have also performed onshore FAT and offshore SAT on the Buzzard Platforms SRP pumps and provided vibration analysis and diagnostics advice on the SRP packages to identify the cause of regular motor bearing failures. Recommendations we provided were accepted which required redesign of the bearing housing to allow for a bearing change / modification. These SRP pumps have now remained in service for over 6 years with out the bearing problem reoccurring.
We have been providing condition monitoring services on a sub-contract basis to John Crane (JCAMS) for many years. We have been involved with many of their client’s, Sinopec Repsol (Talisman), assets including Claymore platform, Piper Bravo, Auk Alpha, Buchan Alpha and Tartan. SAVE have investigated many noise and vibration problems and performed many vibration severity and commissioning works on a variety of Sinopec’s assets, including Claymore’s CCU LP/HP Compressor, Gas Compressor B, and John Brown Power Generators, and piper Bravo’s 3rd Stage Compressor investigation.
SAVE were also responsible for the routine condition monitoring contracts on both the Auk Alpha and Buchan Alpha platforms. Our main responsibilities included the routine measurement and analysis of vibration data, upload and download of data and management of the Omni-trend vibration analysis database, collection and management, and analysis of all oil samples, routine analysis and reporting of all exceptions found, and audits of the vibration database to ensure that alarm set points and measurement parameters, and schedules were relevant and justified and up to date.
On behalf of our client, SAVE performed the day to day management and planning of XPD8 Solutions clients’ condition monitoring program. This program included the routine onshore and offshore vibration data collection, analysis and reporting for the Ninian Central and Ninian North Platforms. This contract required routine monitoring of critical and balance of plant equipment. This was typically performed over a 28 day cycle. The main services include vibration monitoring and analysis, oil analysis, and pump performance testing for Fire Water Systems, Cooling Water, Heating Water Systems, and Water Injection Systems.
Additional services include trouble shooting of hard ware, and software packages. Diagnostics and prognosis for the monitored equipment which have developed failure modes. Reporting is controlled through a centralised reporting database tool, which enables detailed historical searches to be performed.
SAVE were also awarded the Design and build contract for the Ninian assets CSI AMS Suite vibration databases. This also included the provision of training for XPD8 Solutions client personnel.
SAVE have performed feasibility studies for the provision and supply of routine vibration monitoring hardware on 6X power generator sets across the field. The client’s requirements were very demanding due to the hazardous environment where the equipment was to be located. All equipment had to be I/S, including the high temperature transducers for the PT hot end bearings. At the time there was no I/S High Temperature accelerometer available on the UK market to meet the client’s requirements. SAVE located a manufacturer who was both able to and willing to produce the required high temperature I/S accelerometers. The client has since raised a purchase order for the specified hardware with XPD8 Solutions.
Occasional acoustic surveys have also been performed. These include baseline noise and vibration monitoring of new or newly reconditioned machinery such as Gas Generators, Fire Water Pumps, Emergency Generators, Water Injection Pumps, Main Oil Line Pumps, Gas Compressors, Air Compressors, Fans, Gearboxes, and electric motors.
During the exhaust stack redesign on the Ninian North Platform, SAVE were requested to perform a vibration transmission assessment of the machine structural framework, vibration isolators and the supporting base plate. This was to assess the transmitted vibration amplitude from the framework through the isolators to the base plate, when the 18MW power generator was running at full load. This information was then used to identify the excitation frequencies likely to coincide with the new exhaust system stacks natural frequencies.
Routine onshore and offshore condition monitoring services to Centrica Energy Hydrocarbon Resources Limited (HRL) on behalf of AVT. Centrica HRL includes both an onshore and offshore gas processing and production facilities. The 4x onshore assets include both sweet and sour gas processing, which is then supplied to the National Grid. There is also a dedicated condensate storage facility which forms part of this site.
Our main roles and responsibilities are very similar to those detailed above, except that we offer routine support rather than a full day by day service. We are in regular contact with all AVT Staff and also with Centrica Energy personnel. We have also performed offshore services for Centrica HRL on their production platforms in the Irish Sea.
We have also provided ad hoc senior engineering services to many of AVT’s clients, including Centrica and Shell. These surveys include machinery vibration acceptance testing of new plant equipment for Centrica Energy. This includes an acceptance test for a new Fuel Gas Compressor motor for the offshore production platform. SAVE also provided multi-channel vibration assessment of gas generators, and gas compressor trains for Shell.
Some of AVT’s non-oil and gas clients that SAVE have sub-contracted to include Viridor Waste Management, and Billerud Beetham Ltd paper mills. Both of these contracts included the routine vibration analysis and diagnosis of impending machinery failures and formed the backbone for the clients Preventative and Predictive Maintenance programs.
Since forming in 2007, SAVE has provided a range of onshore acoustic and vibration services to Con Mon (International) Ltd. The main roles and responsibilities include vibration and noise trouble shooting and fault diagnosis of high speed rotating and reciprocating equipment.
SAVE provide onshore consultancy services, and noise and vibration acceptance testing for Gardner Denver’s full range of gas compressors. We advise our client where appropriate on the best practice methods for testing, and also on the recommended corrections to reduce noise and vibration. We also provide training to Gardner Denver personnel in the use of noise measurement equipment. All acceptance testing procedures follow the appropriate BS, ISO or NORSOC standards.
SAVE provide onshore and offshore consultancy services, and noise and vibration trouble shooting for Brush Engineering on their Power Generators. We advise our client where appropriate on the best practice methods for testing, and also on the recommended corrections to reduce noise and vibration. All acceptance testing procedures follow the appropriate BS, ISO or NORSOC standards.
Routine onshore and offshore condition monitoring services to Centrica Energy Hydrocarbon Resources Limited (HRL), on behalf of our client. Centrica HRL includes both onshore and offshore gas processing and production facilities. The 4x onshore assets include both sweet and sour gas processing, which is then supplied to the National Grid. There is also a dedicated condensate storage facility which forms part of this site.
Our main roles and responsibilities are very similar to those detailed above, except that we offer routine support rather than a full day by day service. We are in regular contact with both client Centrica Energy personnel. We have also performed offshore services for Centrica HRL on their production platforms in the Irish Sea.
Additional to this, we have provided ad hoc senior engineering services to many of our clients. These surveys include machinery vibration FAT/SAT acceptance testing of new plant equipment for Centrica Energy. This includes an acceptance test for a new Fuel Gas Compressor motor for the offshore production platform. We also provided multi-channel vibration assessment of gas generators, and gas compressor trains for Shell.
SAVE have provided CM services to Talisman (Repsol) for many years. In this time we have provided a combination of routine CM services and ad hoc investigation and RCA’s on Talisman (Repsol) Auk, Piper B, Saltire, Claymore, Tartan, and Thistle platforms, and also on the Buchan (5 pod submersible). We have used best available techniques for this client to both identify and diagnose faults at the first on set of failure, and to proactively build a business case with the client for maintenance intervention on each failure. By introducing a program of FAT and SAT acceptance testing of all new or newly reconditioned equipment, the client has significantly reduced the premature failure rates of their equipment.
Routine onshore and offshore condition monitoring and Reliability Engineering services to Nexen.
Our main roles and responsibilities are very similar to those detailed above, except that we provided routine support as a senior CM and RE consultant at both our offices and at the client’s offices and offshore assets. We are in regular contact with all client and Nexen. We have performed many onshore FAT and offshore SAT acceptance tests and vibration investigations on the SRP package to identify the cause of regular motor bearing failures.
Acting as a Senior Engineer, SAVE’s representative was sub-contracted to the Nexen Condition Monitoring contracts for the Buzzard, Scott and Golden Eagle platforms. A large part of the role was mentoring the clients’ VA1 and VA2 vibration analysts responsible for performing the routine vibration data collection and first line analysis, and providing detailed analysis of off line monitored machine condition (GE Snap Shot) and online machines (GE BN3500 and System 1), presentation of results and reporting of recommendations.
Additional services include regular ad hoc vibration call off investigations. A typical example of this was an investigation in to a problematic Sulphate Reduction Package (SRP) motor bearing failure. Scenic Acoustic evidence was used during the RCA. Our data indicated a rapid deterioration of the bearing, and bearing analysis had indicated a rub and discolouration due to heat. The bearing analysis ruled out water ingress and contaminants as a cause of the failure. The outcome of the initial RCA was to perform a clearance check of the bearings. The inspection revealed that there was a restricted clearance. A laser alignment trend of the motor and skid revealed misalignment was occurring when operating at maximum thermal growth. The RCA outcome was to use a different bearing specification for the motor DE and NDE bearings. To date, further bearing failures have not reoccurred.
SAVE have also performed Motor Current Signature Analysis, and Partial Discharge assessments on the Buzzard platform.
Acting as a Senior Engineer, SAVE’s representative was sub-contracted to the Premier Oil Condition Monitoring contracts. A large part of the role was mentoring VA1 and VA2 vibration analysts performing the routine vibration data collection and first line analysis and providing detailed analysis of off line monitored machine condition (Omni-trend) presentation of analysis results and reporting and recommendations.
We have also reviewed the results of onshore FAT and offshore SAT acceptance tests and have provided many diagnosis’s and solutions during vibration investigations.
Vibration velocity, acceleration and Spike Energy levels were monitored as part of a scheduled condition monitoring program from a Variable Speed Drive motor driving the Yankee Cylinder on paper machine. Over a period of six months, the NDE motor bearing amplitude began to increase and the spectral plot developed a high frequency haystack between 120Kcpm and 185kcpm (2000 – 3083HZ). This was superimposed with harmonics of BPFO, which grew to a maximum peak velocity amplitude of 0.8mm/s.
The Spike Energy spectra also developed high frequency, not synchronous harmonics with a frequency spacing between the harmonic peaks equal to BPFO defect frequency.
The overall Spike Energy amplitudes became very erratic between the measurements with amplitudes fluctuating between 5g and 30g. Overall Peak to Peak Spike Energy amplitudes exceeded 30g at the highest point.
Based on the diagnostics it was suspected that the bearing had been exposed to EDM. Maintenance intervention was performed, and the motor bearings were removed and inspected for signs of damage. During the visual inspection prior to the motor removal and disassembly, the motor earth brush was also inspected and was found to be worn. The armature (loading spring) was also worn and was sticking so it was not providing uniform pressure to the brush.
On inspection of the NDE bearing, classic signs of EDM damage were found. The outer race showed distinct fluting which covered the entire annulus of the outer and inner bearing races. The fluting was much heavier in the loaded zone. The inner race had even, but much less severe fluting that the outer race. The balls also all had a dull surface finish to them.
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