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USING NEAR-REAL TIME MONITORING TO IMPROVE EQUIPMENT RELIABILITY
- 2. PREDICT – ACT– PROTECT • Predict - Equipment monitoring provides opportunities to extend equipment availability through predictive maintenance • Act – Data analysis creates opportunities to better understand operating conditions for intervention • Protect – Understanding empowers corrective action to protect and improve equipment, even during transient operation
- 3. Equipment Monitoring –Current State Operator Monitoring • Once per shift • Limited data points • Time-consuming • Low connectivity to other systems and groups Process Monitoring • Process variables only • Limited visibility outside operator groups • Limited adjustment points Machinery Protection Systems • Expensive • Tied into equipment control • Limited fundamental understanding • Limited equipment Vibration Rounds • Once per month/quarter • Time-consuming • Requires highly trained personnel • Time spent on equipment with no issues • Misses idle spare equipment
- 4. Predict Act Protect Intelligent fluid motionInsight provides more opportunities to improve 4 • Operator Monitoring • Process Monitoring • Machinery Protection Systems • Vibration Rounds • 12 (or fewer) chances per year to understand Conventional Methods • Wireless Monitoring • Trends every 30 minutes • 17,280 opportunities per year to Improve Condition Monitoring • Engineered Analytics • Full insights every 30 seconds • 1 Million opportunities per year to Predict Predictive Analytics
- 5. 5 IoT Solutions Basedon Equipment Criticality WIRELESS CONDITION MONITORING (80% of assets across balance of plant) Near-time wireless monitoring (15/30 minutes) with alerts, trends and instant notifications PREDICTIVE ANALYTICS (20% of assets that are critical to production) Real-time monitoring and diagnostics with recommendations Critical Systems: 5% Key Processes: 15% Balance of Plant: 80%
- 6. Complete IoT Solution: 1.Customers need insights to detect problems before they lead to downtime. 2. Flowserve Monitoring Center helps customers to understand field readings and provide corrective actions. 3. Flowserve’s Insight portal provides a secure visualization and predictive analytics cloud platform, tailor made for pumps, seals and valves monitoring. 4. Flowserve’s wired and/or wireless sensors installed on equipment reliably gather performance data. 5. Flowserve’s Global Quick Response Centers are ready to support customers and take recommended actions. 6 Cloud PlantMaintenance PlantOperations and Planning PlantReliability and Engineering GlobalFlowserve Service Network Flowserve Monitoring Center Pumps,Seals and Valves Flowserve IoT System Design PREDICT ACT PROTECT
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- 8. Insight Portal –Predictive Analytics – Transient Analysis 8
- 9. Insight Portal –Predictive Analytics – Transient Analysis 9
- 10. Insight Portal –Predictive Analytics – Transient Analysis 10
- 11. 11 Red Raven preventedfailure from cavitation event on 60-year-old Flowserve water pumps in steel mill • US based steel mill facing long standing flow recirculation issues on river water pumps • Flowserve predictive analytics quickly detected and diagnosed operating conditions • Team provided improved operating regime to prevent further failures and how to improve efficiency • Customer able to adjust operations and return equipment to service quickly Red Raven unique predictive analytics can not only detect, but also diagnose failures … before they occur.
- 12. 12 Red Raven empowereda plant operator to quickly detect, diagnose, and prevent equipment failure … allowing them to provide stable, reliable power • UK power plant facing on-going reliability and unpredictable maintenance issues • Flowserve cloud-based condition monitoring and predictive analytics installed on flow control equipment • Red Raven within days detected upstream boiler upset conditions and prevented catastrophic pump damage • Customer able to adjust operations and return equipment to service quickly with Flowserve field support Red Raven enables digital, real-time connections between customers, their flow control equipment, and Flowserve technical experts
- 13. 13 Red Raven’s customersupport capabilities helped a UK power operator prevent further damage or injury • UK based power plant had a “unusual” vibration event just after midnight on a cooling fan • Red Raven condition monitoring detected the anomaly, and our team notified the operator • Customer adjusted operations until visual inspection in the morning revealed a significant “bird strike” • Further damage to the fan and the surrounding equipment was avoided Red Raven provides automated alerts and alarms on critical operating equipment, and can help prevent further damage to surrounding equipment and personnel
- 14. The IoT Journeyto Improved Reliability Predictive Analytics Artificial Intelligence, Digital Twin System Condition Monitoring • Wireless connectivity • Historical trends and comparison • Alerts & Alarms • Wired data collection • Wireless transmission to cloud • Algorithms to detect/predict selected fault conditions • Digital Twin modelling • Simulate and then implement • Leverage on Big Data • AI/ML algorithms to predict fault conditions • System level analytics on the connected process • Energy transition • Energy efficiency Rotating Equipment • Pumps • Fans / Blowers • Agitators • Conveyors Valves Seals – coming soon Motors – future development Full-System View
Editor's Notes
- #12 For further details, contact Francesco Gasparri: Fgasparri@flowserve.com
- #13 RedRaven Diagnostics Enable Streamlined Power Supply in the UK Challenge To maintain high standards of delivering uninterrupted supply of power an energy company in the UK was looking for a way to upgrade condition monitoring processes and leverage next-generation predictive analytics capabilities. Solution SSE explored cloud-based condition monitoring options with predictive analytics for feed pump performance and maintenance. Today, SSE wirelessly monitors their plants, receives near-real-time upset condition alerts, and more accurately predicts when pumps will require maintenance with RedRaven. Empowering plant operators to prevent unnecessary disruptions The Utilities business unit of SSE Enterprise (SSE) delivers energy to local industrial estates in the UK, including several manufacturing plants. These estates rely on a stable power supply, and any disruption could result in substantial revenue loss and expensive fines. Industry-standard monitoring protocols include costly biannual site visits to check vibration levels. Too often, such visits only reveal limited, outdated pump condition and performance snapshots. Flowserve proposed that SSE consider RedRaven, an adaptive technological platform, enabling internet of things (IoT) services for flow motion equipment and systems. “Flowserve demonstrated RedRaven’s wireless monitoring solutions and analytics capabilities,” said Guy Hawkswell, Electrical Control and Instrumentation Engineer for SSE. “After they explained how the system securely transmits performance data and the various service levels with experienced technician data trend reviews, we decided to deploy a trial demo kit.” RedRaven proactively identifies an upset condition Flowserve installed wireless sensors on two boiler feed pumps and six auxiliary pumps. It wasn’t long before Flowserve technicians discovered an upset condition. While analyzing pump data, technicians noticed an increased load on the boiler. Data confirmed the pump was running a higher temperature and vibration level than usual. After investigating the issue, SSE and Flowserve analytics personnel identified fuel source as the root cause. Physical inspection further proved the boiler was burning abnormally wet wood, causing a boiler flare-up, raising the boiler feed water operating temperature. Although the flare-up may not have caused catastrophic damage, the incident proved the value of RedRaven’s Predict, Act, and Protect protocols in delivering SSE’s primary marketplace deliverable: uninterrupted power supply. Streamlined maintenance protocols with RedRaven Flowserve changed the frequency of data collection to yield greater insights, further enhancing SSE’s ability to proactively self-correct plant operations. Continuing through trial phase, Flowserve’s monitoring center personnel helped SSE respond to upset conditions and take action to prevent equipment failures. The ability to predict required pump maintenance enables SSE to distribute resources more efficiently. Now they can dispatch technicians only when necessary, instead of routinely sending technicians to inspect healthy equipment. And now, instead of requiring technicians to collect data and upload it to an internal system for analysis, the process is automated with SSE, greatly reducing errors, and expediting data delivery and analysis. Perhaps the most significant benefit SSE is experiencing with RedRaven is the increased integrity of their supply stability. SSE’s customers are not concerned with IoT systems, equipment sensors, data trends or analytics. What’s important is that SSE consistently supplies them with power to run their operations. RedRaven increases SSE’s success in continuing to deliver on that promise. “It’s important for us to have Flowserve as a partner in this,” said Hawkswell. “They provide IoT solutions that are easy to understand and implement. And installation is very quick – in our case, it was under an hour. Flowserve also set up a stand-alone IoT system that didn’t interfere with our process or communications. RedRaven can collect our data, analyze it, and come back to us if there is a problem while we’re able to concentrate on our business.”
- #14 For further details, contact Francesco Gasparri: Fgasparri@flowserve.com
- #15 Flowserve has been at the forefront of exploring & rolling out the latest tech We today have a platform ( RedRaven) capable of providing Condition monitoring and Predictive Analytic capabilities. We will continue to enhance these. ( Also to note – CM & PA have been launched, but the work do not stop as we continue to enhance these with latest tech and algorithms to detect even more conditions) Digital Twin & ML AI is gaining rapid traction due to their advanced capabilities to tie real world and digital data, and this will fuel many of Flowserve’s capabilities The path forward will be to continue to tie in at a system level for the connected factory and aid the customer in achieving the goals of their Energy transition journey