Process Automation and Remote Condition Monitoring...
Transcript of 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
GEA Mechanical Equipment
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
GEA Mechanical Equipment
Acid Dosing System
3 Process Automation and Remote Condition Monitoring for Centrifuges
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
GEA Mechanical Equipment
Shut off valve
Caustic Dosing System
4 Process Automation and Remote Condition Monitoring for Centrifuges
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)
GEA Mechanical Equipment
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
5 Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
Semi-automatic plant with automatic dosage system
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
6 Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
Semi-automatic plant with automatic dosage system
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
7 Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
Semi-automatic plant with automatic dosage system
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
8 Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
Fully-automatic plant (Automatic start and shut-down)
9 Process Automation and Remote Condition Monitoring for Centrifuges
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
GEA Mechanical Equipment
Fully-automatic plant (Automatic start and shut-down)
10 Process Automation and Remote Condition Monitoring for Centrifuges
Shut down: • Draining of crude oil tank • Draining of reactor tanks • Automatic shut down
(stop pumps and change of valve position)
GEA Mechanical Equipment
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)
11 Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
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
12 Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
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
13 Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
Fully-automatic CIP (CIP Cleaning In Place) for centrifuge and plant
14 Process Automation and Remote Condition Monitoring for Centrifuges
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.
GEA Mechanical Equipment
Loss Monitoring
15 Process Automation and Remote Condition Monitoring for Centrifuges
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
GEA Mechanical Equipment
Remote View and remote control
16 Process Automation and Remote Condition Monitoring for Centrifuges
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
GEA Mechanical Equipment
Fundamentals of Oilseed and Edible Oil Processing and Refining Short Course, Shanghai, 2014 Robert Zeldenrust
Remote Condition Monitoring for Separators
GEA Mechanical Equipment
Maintenance Philosophies
18 Process Automation and Remote Condition Monitoring for Centrifuges
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.
GEA Mechanical Equipment
Remote Condition Monitoring of Separators
19 Process Automation and Remote Condition Monitoring for Centrifuges
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
GEA Mechanical Equipment
Remote Condition Monitoring Monitoring Parameters
20 Process Automation and Remote Condition Monitoring for Centrifuges
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.
GEA Mechanical Equipment
Remote Control Online Communication Set-Up – Alarms
21 Process Automation and Remote Condition Monitoring for Centrifuges
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
GEA Mechanical Equipment
Remote Control Description of Devices
22 Process Automation and Remote Condition Monitoring for Centrifuges
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
GEA Mechanical Equipment
Remote Control Example WatchMaster Installation on a Separator
24
Customer
WS Headquarter Oelde WEBPORTAL wewatch
Server
Public Internet Firewall Customer Firewall Provider
Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
Webportal: Separator Overview
The process data gained from the control unit is shown in real time.
25 Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment 26
Webportal: Process data
Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
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
Process Automation and Remote Condition Monitoring for Centrifuges
GEA Mechanical Equipment
Remote Control Monitoring Information to customer
28
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 for Centrifuges