1、Main ten ance Practices GPA Technical Section M Revised December 2001 Maintenance Practices - GPA Technical Section M Revised December 200 1 Dan Haun Brian Perkins Introduction for 200 1 Maintenance Management Practices October, 200 1 Aces BP In recognition of GPAs desire to share information and to
2、 facilitate continuous improvement within the operationslmaintenance discipline of the gas processing industry, a cross section of industry representatives came together to develop a publication that would support GPNGPSA in achieving this endeavor. The intent of this publication is to provide a bas
3、ic understanding of maintenance management practices and information on some of the tools available to assist in improving safety, environmental, and overall asset performance. These practices are representative of the current time and environment and should be periodically reviewed and updated for
4、changes as is expected through continuous improvement.“ Dave Keanini Western Gas Resources, Inc. I 1 MikeSpinks 1 Coastal I Tom Spaulding I Cooper Energy I Andy Deck Enogex Pete Rasmussen ExxodMobil Dennis Castro KN Energy l I PeterLynch I os1 1 BobStubbs 1 Phillips I l I Ajey Chandra I Purvin intru
5、sive and non-intrusive. Intrusive tools are those that require removal of the equipment from service. Non-intrusive inspections do not require an equipment outage and rely on indirect indicators to determine the condition of the equipment. The trend within industry has been to move to non-intrusive
6、inspection techniques whenever possible. This practice, sometimes called Condition Based Maintenance, utilizes condition monitoring and predictive maintenance technologies to determine when corrective maintenance is necessary. The proven theory is that over time, less total maintenance cost is incur
7、red with Condition Based Maintenance than that of the more intrusive traditional preventive maintenance. Preventive maintenance is typically directed at time based equipment repairs, restoration and overhauls. Condition monitoring and predictive maintenance are effective techniques to determine the
8、onset of an equipment failure, provided it is not instantaneous, and can be trended with the proper tools and techniques. Routine process variable monitoring, also known as surveillance monitoring, is most often done by operations personnel and is the most widely used method of condition monitoring.
9、 Predictive Maintenance technologies utilize various techniques. They are all designed to detect failure effects, which fall into the categories of dynamic, particle, chemical, physical, temperature, or electrical effects. Dynamic effects include abnormal amounts of energy, such as increased vibrati
10、on and acoustics (noise levels). Particle effects include an increase of particles released into the environment, such as in lubricating oils and from corrosion products. Chemical effects include traceable quantities of chemical elements released into the environment, such as wear metals. Physical e
11、ffects include changes in appearance or structure, such as with dimensional changes, cracks, or visible effects of wear. Temperature effects include abnormal rises in temperature. Electrical effects include changes in resistance, conductivity, dielectric strength or potential. Preventive Maintenance
12、 is desirable when Condition Monitoring or Predictive Maintenance is not practical or cost effective if it reduces the risk of the failure to an acceptable low level and at an acceptable cost. If a preventive task cannot be found which reduces the risk of the failure to an acceptable low level, cons
13、ideration should be given to redesign the equipment. Section V. - Maintenance Tools and Applications, Page 1 of 34 Maintenance Practices - GPA Technical Section M Maintenance Tools and Applications - Revised December 2001 Maintenance Tools Task Acoustic Emission Inspection Acoustic Monitoring Leak D
14、etection AdjusVAlign Air Conditioner Performance Test Frequent Operatinci Parameters Monitring Cali brate Capaci ty Test Discharge Change Lubricant Charger DC Current Analysis Charger Voltage Sampler and Comparator Test Check Calibrate Check Lubricant Level Clean and Inspect Coating Test/ Wet Film T
15、hickness Coating TestlDry Film Thickness (for Ferrous Substrates) Combustible Gas Analysis Combustion Chamber Internal Boroscope Inspection Commutation Electrical Neutral Test Commtator Circularity Test 4pplies To: ressure vessels, stressed structures and :urbines or gear boxes. 4ny component having
16、 fluid flowing through it. Somponents, bel chain jrives, etc. with adjustments. 411 air conditioning systems utilizing a centrifugal compressor and freon gas. Engines Instrumentation Rechargeable dry and wet cell batteries. Components with circulating lubricant svstems. Battery charging system. Batt
17、ery charging system. Instrumentation which can have a test signal applied. All components with oil sumps and grease reservoirs. Mechanical casings, electrical contacts, circuit cards, welds. Stationary Equipment or any surface with a solid, smooth surface. Stationary Equipment with Ferrous Substrate
18、s Liquid filled transformers with nitrogen seal or conservator svstem. Engines DC Motors/ Generators DC Motors/ Generators Comments Disadvantage- Intrucive task may require equipment shutdown Disadvantage- Intrucive task may require equipment shutdown Disadvantage- Intrusive task may require equipme
19、nt shutdown Disadvantage- Intrusive task may require equipment shutdown Disadvantage- Intrusive task may require equipment shutdown Disadvantage- Intrusive task will require equipment shutdown Disadvantage- Intrusive task may require equipment shutdown Disadvantage- Intrusive task may require equipm
20、ent shutdown Section V. - Maintenance Tools and Applications, Page 2 of 34 Maintenance Practices - GPA Technical Section M Maintenance Tools and Applications - Revised December 2001 Task Commutator Surface Inspection Applies To: DC Motor/ Generators Component Signature Identification Compressor perf
21、ormance Test Control Valve Condition Assessment Cycle/Rotate Cylinder Pressure Monitoring DC High Potential Test DC Voltage and Ripple Tests Dehydrator Performance Test Differential Pressure Measurement Disassemble and Inspect Electronic components. Ail types of compressors, vacuum pumps and blowers
22、 Control Valves Components that cycle and rotate. Diesel and Gas Engines AC/DC Machines, Transformers Power supplies in electronic components. All rejuvenation air dryers, high and low pressure applications Filters, ion exchangers, dem i neral izers and heat exchangers. Any component. I Ferrous Subs
23、trates Dry Film Thickness (for Non- ferrous Substrates) Comments Disadvantage- Intrusive task Stationary Equipment with Ferrous and Non- may require equipment shutdown Disadvantage- Intrusive task will require equipment shutdown Disadvantage- Intrusive task may require equipment shutdown Section V.
24、- Maintenance Tools and Applications, Page 3 of34 Maintenance Practices - GPA Technical Section M Maintenance Tools and Applications - Revised December 2001 rask Sddy Current (ET) Inspection Electro-magnetic Interference (EMI) Susceptibility Electrolyte Analysis Engine Performance Test Engine Analyz
25、er Engine Emission Analyzer Fan Performance Test Fiber Optic Monitoring ( Boroscope) Fuel System Internal Inspection Generator Rotor-Shorted Turns Monitoring Test Head/Flow Test Heat Exchanger Efficiency Heat Transfer Coefficient Hydrostatic Test In-leakage Detection Infrared Thermographic Inspectio
26、n Applies To: Thin-walled vessels, like heat exchanger tubes, “Spot checks“ on all types of surfaces Electronic components. Rechargeable wet cell batteries. Diesel and Gas Enaines Gas Engines Diesel and Gas Engines Ventilation fans. Applicable to all component internais accessible to the inspection
27、probe. All fuel systems. AC Generators Centrifugal pumps Heat Exchangers All types of heat exchangers. Pressure retaining com ponen ts Condensers, valves, flanges, condensate, steam and feed water systems. Electrical: power generating equipment, power distribution system, and motors. Mechanical: val
28、ves, boilers, steam distribution systems, and pumps, Comments Disadvantage- Intrusive task may require equipment shutdown Advantage- The most comprehensive and efficient way of determining the condition of slow speed engines Disadvantage- Intrusive task may require equipment shutdown Disadvantage- i
29、ntrusive task may require equipment shutdown Disadvantage- Intrusive task may require equipment shutdown Disadvantage- relatively high cost for purchase of inspection equipment. This service can typically be purchased cost effectively. Section V. - Maintenance Tools and Applications, Page 4 of 34 Ma
30、intenance Practices - GPA Technical Section M Maintenance Tools and Applications - Revised December 2001 AC/DC Motors Detectors, transmitters Polarization Index Measurement Insulating Liquid Sample Check ion Exchanger Performance Test) Liquid Penetrant (PT) Lubricate I Machine Running Current - Moni
31、toring Magnetic Particle (MT) I inspection Micro Ohmmeter Test Mi I I ivolt DroD Test Monitor Eledrical Parameters and Valve Monitor Temperature Motor Current Frequency Spectrum Analysis Motor Current Time Domain Analvsis Motor Runnin Current Test Network Anal sis Running , Analysis I Task WDC Machi
32、nes, rransformers 31 circuit breaker, Iry or wet cell batteries lemineralizers, Ion Zxchangers, water ither pressure retaining :om ponents. 3il circuit breakers, oil I il led transformers. 411 parts with non- absorb ng surfaces. Yote: Bleed-out from 3orous surfaces can mask indications of defects. B
33、earings, shawpacking surfaces, valve stems, hinges, mechanism joints, relays. AC/DC Motors and Generators Ferromagnetic materials; bar, forgings, weldments, extrusions Air circuit breakers. Air circuit breakers. Motor operated valves. Turbines, com pressors, pressure vessels, heat exchangers, engine
34、s, pump Bearings on rotating equipment, compressors, turbines, gear boxes, engines, and electronic panels. AC/DC motor systems I and motor generators ACIDC motor drive systems Section V. - Maintenance Tools and Applications, Page 5 of 34 Maintenance Practices - GPA Technical Section M Maintenance To
35、ols and Applications - Revised December 2001 Oil Analysis Open and Inspect Over Current Trip Device Test Power Factor Test Pump Efficiency Monitoring Pump Performance Test Pressure-Volume Analysis Power Supply Harmonic ASME BPV Code, Section V. Name: Acoustic Monitoring Leak Detection Applies To: An
36、y component having fluid flowing through it. Definition: The acoustic emission transmitted through the component wall can reveal defects in the valve and software. This can be accomplished either by open system normal flow and comparison of acoustic energy transmitted by good valves or with valves s
37、hut and testing to down stream pressure. Name: AdjustlAlign Applies To: Components, belt/ chain drives, etc. with adjustments. Definition: Brings the component to design or desired operational condition from a wear or shock induced position. This is generally a condition driven technique, but the size of the component or the operating environment may suggest periodic accomplishment. Section V. - Maintenance Tools and Applications, Page 8 of 34
