process automation and remote condition monitoring...

GEA Mechanical Equipment

Fundamentals of Oilseed and Edible Oil Processing and Refining Short Course, Shanghai, 2014 Robert Zeldenrust

Process Automation and Remote Condition Monitoring for Centrifuges and Plants


Degree of Automation

2 Process Automation and Remote Condition Monitoring for Centrifuges

Standard level – Semi automation • Automated dosing of chemicals • Loss monitoring • Manual switch of product flow during start-up, shut down and CIP Optional level – Full automation • Also fully automated start-up, shut-down and CIP procedures


Acid Dosing System


LSH

LSL

FE

FFIC Acid Storage tank

NRV Shut off valve

PLC Signal

Acid filling line

M

Oil

Acid circulating pump

Dual strainer

Dosing valve

Pressure relief valve

Automated follow-up control of acid flow in relation to the crude oil flow


Shut off valve

Caustic Dosing System


LSH

LSL FE

FFIC Caustic storage tank

NRV Shut off valve

PLC Signal Caustic filling line

M

Oil

Caustic circulating pump

Dual strainer

FE

FFIC

PLC Signal

Hot water Mixer

Pressure relief valve

Dosing valve

Dosing valve

Automated follow-up control of caustic soda and diluting water in relation to crude oil flow, acid dosing and FFA content (manual input value)


Semi-automatic plant with automatic dosage system

Control of metered addition as a function of crude oil parameters.

Calculation of • acid • caustic • water

Metering parameters




Control of metered addition as a function of crude oil parameters. Parameter archive for density • FFA content • Mol weight FFA • initial concentration

Possibility to handle individual kind of oils. Identification of percentage with the help of “Baume“ table.

Dosing parameter archive and Baume table




Previous process data (HDA - historian data access) • Process data viewer

(graph and numerical value) • Archive data backup Control of dosage • Actual value • Target value • Control value

Alarm logging • High high value • High value • Low value • Low low value • Deviation between actual and

target value (XD).

Previous process data




Selection / adjustment of Separator • Timer (e.g. Start separator,

partial and total desludging) • Fine tuner (e.g. CIP and

production)

Process data viewer, graph and numerical value of operating conditions. • Archive data backup • Motor current • Desludging (total and partial) • Start / Stop of Machine and

production • Operating water • Vibro- and speed control



Fully-automatic plant (Automatic start and shut-down)


Start • Automatic switch of valves • Heating oil (temperature

control) • Circular flow • Automatic switch of valves

for production • Automatic preparation of

separator for heavy phase • Separator time start • Change of fine tuner position • Partial desludging


Fully-automatic plant (Automatic start and shut-down)


Shut down: • Draining of crude oil tank • Draining of reactor tanks • Automatic shut down

(stop pumps and change of valve position)


CIP

CIP - “Cleaning In Place”

• CIP is a cleaning procedure commonly used for centrifuges and heath exchangers.

• Frequency of application : • 1 x week

• Nevertheless and for safety reasons, the separators have to be opened and cleaned / checked thoroughly every 3 - 6 months (this includes a verification of the disc stack)



CIP - Equipments

Caustic Acid

from the separator / plant

to the separator / plant

Circulation line for preparation of the solutions

TIC TIC Water +

Acid

Water +

Caustic

max. 55°C

max. 80°C CTIHL

Steam

Condensate PI



CIP – Procedure

Steps of CIP • Filling the CIP vessels with process water • Preparing the caustic and acid solutions

o Caustic: solution 2,5% (140 µS/cm) max. 80°C o Acid: solution 0,5% ( 7 µS/cm) max. 60°C o Heating up of CIP solutions

• Cleaning the equipment with hot water • Flushing with hot caustic solution • Push out the caustic solution with hot water • Flushing with hot acid solution • Flushing with hot water until neutral • Centrifuges: proceed with a full discharge



Fully-automatic CIP (CIP Cleaning In Place) for centrifuge and plant


Possible pre-selection of CIP steps: • Preflush (Water – Oil- Drain) • Caustic step 1 • Caustic step 2 • Intermediate flush • Acid step 1 • Total desludging • Acid step 2 • Total desludging • Final rinse • Total desludging

Conductivity parameters can be changed by the customer. With reach of the measuring values the next function starts.


Loss Monitoring


Functions: • Measurement of crude

oil flow • Measurement of refined

oil flow • Summation of crude oil

flow • Summation of refined oil

flow • Actual refining loss • Average refining loss


Remote View and remote control


Support for control system a) Support for operating b) Analyse operating status

of machine and plant components

c) Modification of software at SCADA system and PLC


Fundamentals of Oilseed and Edible Oil Processing and Refining Short Course, Shanghai, 2014 Robert Zeldenrust

Remote Condition Monitoring for Separators


Maintenance Philosophies


Years Maintenance strategy

Maintenance approach

Signification Human body analogy

1950-1970

Breakdown Maintenance

Fix-it when broken

Large maintenance budget

Heart attack or stroke

1970-1990

Preventive Maintenance

Scheduled maintenance

Periodic component replacement

By-pass or transplant surgery

1990-2005

Predictive Maintenance RCM

Condition based monitoring

Maintenance decision based equipment condition

Detection of heart diseases using EKG or ultrasonic

2005- Proactive Maintenance RCM

Detection of sources of failure

Monitoring and correcting failing root causes

Cholesterol, blood pressure monitoring with diet control

Maintenance philosophies have changed dramatically within the last 50 years.


Remote Condition Monitoring of Separators


With condition monitoring customers get a forward-looking service technology.

ongoing status monitoring

diagnosis of processes & centrifugal separating technology

early indication of wear-and-tear

optimize maintenance interval scheduling

ensure maximum reliability and productivity

enhance Safety

maximize costs control and secure

investment planning

simplify Root Cause Analysis evaluation

24/7 data recording and trending


Remote Condition Monitoring Monitoring Parameters


What can be monitored and which parameters are necessary?

Which parameters or parts can not be monitored?

Bearing conditions Vibration Resonance Process parameter: feed, back pressure or turbidity Machine parameter: motor current, oil temperature or speed

Gasket wear and mechanical wear on bowl parts.


Remote Control Online Communication Set-Up – Alarms


Subsidiary

Internet

Connection

WatchMaster Plus

WS wewatch Server

GEA WS Headquarter

Failure wewatch unit sends Messages to

wewatch server

Simultaneous Alarm messgaes

via SMS and Email for Emergency and Local Service Team

Customer

Support for Subsidiary

Report


Remote Control Description of Devices


Master unit

Via internet

Scope for one machine

Sensors

Evaluation Device

Industry PC

network switch

4 channel analyzing device supplied

in a stainless steel cabinet

GEA Mechanical Equipment 23

Remote Control Description of Devices

Data connection of all machines and

transfer to a central server.

Continuous measured data with detailed

status & trend visualized in the

wewatch Portal.

Machine analyses worldwide via internet.

Access to machine process data &

vibration data, e.g. speed, flow rate,

operating hours, outlet pressure etc.

Satellite units

Master unit

Via internet

Scope for several machines

Process Automation and Remote Condition Monitoring for Centrifuges


Remote Control Example WatchMaster Installation on a Separator

24

Customer

WS Headquarter Oelde WEBPORTAL wewatch

Server

Public Internet Firewall Customer Firewall Provider



Webportal: Separator Overview

The process data gained from the control unit is shown in real time.


GEA Mechanical Equipment 26

Webportal: Process data



Example: Bearing monitoring

27

Remote Control Monitoring is a system for early detection of functional failure.

pre-alarm

main-alarm

Time Changes in vibration notice offline (envelope technology) P-F intervall 1-8 month

Changes in vibration notice Remote Control P-F interval 1-2 month

Point where failure starts to occur

Func

tiona

lity

Audible noise P interval 1-2 month

Heat by touch P-F interval 1-5 days

Functional failure

P1 P2

P3

P4



Remote Control Monitoring Information to customer

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Generation of diagrams for evaluation (to customer) Reports concerning the condition of the machine on demand Alarm handling and reporting in case of a fault indication Report and history management Notification for maintenance and control intervals

(running hour relevant) Quarterly machine health report (depending on service contract)


process automation and remote condition monitoring...

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