we. b.10 sujit chakravarty - ndt · by: mr. sujit chakravarty and ms. tanusree chakravarty...
TRANSCRIPT
By: Mr. Sujit Chakravarty and Ms. Tanusree Chakravarty Mukherjee
• Oil & Gas Industries are facing challenges due to economic downturn.
• Energy Market is shifting more towards eco‐friendly sources of energy.• Reducing green house gases and protect earth from ill effect of globalwarming is the key
• This Economic scenario needs more natural gas based products eitherform of Compressed Natural Gas (CNG) or liquidified fuels in bothLiquidified Natural Gas (LNG) and Gas to Liquid (GTL) forms. Compressorare mandatory part of the process.• Economical benefits of embedded sensors based continuous integritymonitoring is a need for oil and gas industries.
Typical Upstream Gas & Condensate Production and Compression Unit Diagram
Typical Down stream LNG Production Unit Diagram
1 C h t f th t l b d j t1. Compressors are heart of the natural gas based projects.2. Huge investments are involved in both upstream and
downstream gas compression units.3. This has been a trend to have standby compressors to
minimize the impact of failures and uncertainty involvedwith it.
4. An effective Risk Base Inspection (RBI) & monitoringsystem of Compressors will cut down capital expendituredrastically.y
5. Embedded acoustic and vibration sensors will ensurereliable monitoring between two planned outage time.
1. Thermal stress.2 Torsional stress
Compressors have failed due to rotors succumbed to various stress:
2. Torsional stress.3. Stress due to vibration.4. Mechanical stress.5 F ti t5. Fatigue stress.
S f ilSome failures are unpredictable & costly
To eliminate possibility of surprise failure we need embeddedTo eliminate possibility of surprise failure we need embedded monitoring system
• Acoustic sensors
• Vibration sensors
• Data acquisition and transmission
• Data integration and analysis• Data integration and analysis.
• Risk based Inspection software/ program.
• Reliability and cost effectivenessMagnetic Vibration Sensor
Types of Acoustic sensors that is in view
• Piezo‐polymer film sensors.
• Continuous wave inter digital transducers.P tl l i d i i t l {di l t i }
• Gyro‐magnetic acoustic sensors.
• Permanently polarized piezo‐ceramic crystals {dielectric}.
Piezo‐ceramic layers can be used for axial and centrifugal compressor rotors
Suction
Axial Compressor Rotor/ Stator BladesAxial Compressor Rotor/ Stator BladesShrouded Impeller Gas flow
Strategically Placement of Piezo‐ceremic sensors detects development of flaw
Types of vibration sensors that is in view
• Proximity probe type sensor (using Hall Effect)
• Piezo‐electric accelerometer sensors.
•Mechanical vibration sensorsMechanical vibration sensors
Pressure Type
Torque Type
Both Acoustic & Vibration Sensors are going to be integrated in electronic and computing system.
Casings and Bearings
Currently installed equipment in the aging oil & gas reservoirs are nolonger considered to be economically efficient with huge initialInvestment of standby compressor.
The design or maintenance decisions is going to be changed accordingThe design or maintenance decisions is going to be changed accordingto changing market scenario.
Repair costs and safety have a huge drive to apply the probabilistic assessment on rotating equipment.
This process is expected to be another reason to bolster the growth of the embedded acoustic and vibration sensors usage with continuousthe embedded acoustic and vibration sensors usage with continuous health check system.
Embedded acoustic and vibration sensors will ensure reliablemonitoring system together with Risk Base Inspection (RBI) will ensureb d b l l dbusiness economics and sustainability in Oil & Gas Industries.
