Condition monitoring

Condition monitoring

This is a topic page to show an overview of a sub field of Integrated operations, describing the knowledge developed by the IO Center

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Program 3 of Phase I of the IO center supported a project on condition monitoring. The key objective of the project was to document the extent to which state-of-the-art condition monitoring technology actually provides the information necessary for supporting the goal of Integrated Operations. A secondary objective was to define and develop new approaches, methods and technologies for condition monitoring on selected equipment.
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The IO capability stack model describes the different levels of information that is needed to support a true IO organization. The two basic levels in the stack  model describes the processes of data collection, data management, analysis, modeling and prediction. Condition monitoring is a process covering these basic levels, and thus supporting the higher levels in the stack.

Program 3 of Phase I of the IO center supported a project on condition monitoring. The key objective of the project was to document the extent to which state-of-the-art condition monitoring technology actually provides the information necessary for supporting the goal of Integrated Operations. A secondary objective was to define and develop new approaches, methods and technologies for condition monitoring on selected equipment.

SELECTION OF EQUIPMENT FOR CONDITION MONITORING

A survey was carried out in which each of the industry partners in the IO center were asked to prioritize equipment for the purpose of reviewing and testing CM methods and technologies.The top three equipment types were selected for case studies in Program 3. The selected equipment were:

  1. Safety critical valves – internal leakage detection, laboratory test setup
  2. Production separators – non intrusive inspection, laboratory test setup
  3. Heat exchangers – non intrusive inspection, literature study

SAFETY CRITICAL VALVES

The work on safety critical valves was based on previous work carried out in the CORD (Coordinated Offshore operation&maintenance Research and Development) project 2002-2007 where several technologies for acoustic and pressure based detection of internal leakage was tested with respect to the ability to detect and determine internal leakage and size of the leakage.

Program 3 efforts covered two new aspects of internal leakage detection and monitoring. The first aspect was an investigation of scaling effects, i.e. the applicability of results to a large valves (10" – 40") from testing on small valves (2"-4"). The second aspect was to determine whether a more detailed analysis of the acoustic leakage signal could improve the ability to characterize the leakage and how it evolved.

The work was carried out on two test rigs, one with floating ball 4" valve and one with trunnion mounted ball valve 8". Tests were performed both on liquids and gas.

PRODUCTION SEPARATORS

The work on production separators focused on the ability to perform presence detection of internals without the need to open the tank for inspection, i.e. non intrusive inspection. Acoustic and radiographic technologies were used to perform inspection based on a pre-determined set of marker scenarios. The results of the tests were used to evaluate the applicability of the different methods and technologies. Novel approaches such as using internal test tubes for insertion of radioactive sources was tested and evaluated with regard to possible increased detection accuracy compared to increased production cost. A method using acoustic markers was developed and tested.

The laboratory setup was an atmospheric tank 2m in length and 1m in diameter, with main shell thickness comparable to a normal offshore separator. A cyclone was fitted inside on the inlet to provide separation of gas from liquid. The tank was also fitted with a baffle plate, and bottom trays for testing detectability on different types of solids. A circulation pump provided the ability to setup a working flow including two phase water/air circulating through the tank.

HEAT EXCHANGERS

A literature study was performed to determine possible approaches to non intrusive inspection on different types of heat exchangers.

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