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    ME RoTIC 2018 PresentationAbdulrahman Alkhowaiter Final

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    Abdulrahman Alkhowaiter
    This document discusses several new technologies that can improve the reliability, safety, and efficiency of rotating equipment. It provides examples of implementing improved steam turbine designs with electronic trip systems and pneumatic actuators to achieve higher mean time between failures. Another example is retrofitting large steam turbines to replace hydraulic governor systems with electric actuators to eliminate failures from control oil systems. High-speed magnetic bearing compressors are also discussed as eliminating gearboxes, lubrication systems, and couplings for increased reliability. Overall the document argues that adopting new technologies can help prevent machinery failures and improve performance metrics.

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    ME RoTIC 2018 PresentationAbdulrahman Alkhowaiter Final

    Uploaded by

    Abdulrahman Alkhowaiter
    91 views19 pages
    This document discusses several new technologies that can improve the reliability, safety, and efficiency of rotating equipment. It provides examples of implementing improved steam turbine designs with electronic trip systems and pneumatic actuators to achieve higher mean time between failures. Another example is retrofitting large steam turbines to replace hydraulic governor systems with electric actuators to eliminate failures from control oil systems. High-speed magnetic bearing compressors are also discussed as eliminating gearboxes, lubrication systems, and couplings for increased reliability. Overall the document argues that adopting new technologies can help prevent machinery failures and improve performance metrics.

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    2018 Presentation on New Technologies in Rotating Equipment

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    This document discusses several new technologies that can improve the reliability, safety, and efficiency of rotating equipment. It provides examples of implementing improved steam turbine designs with electronic trip systems and pneumatic actuators to achieve higher mean time between failures. Another example is retrofitting large steam turbines to replace hydraulic governor systems with electric actuators to eliminate failures from control oil systems. High-speed magnetic bearing compressors are also discussed as eliminating gearboxes, lubrication systems, and couplings for increased reliability. Overall the document argues that adopting new technologies can help prevent machinery failures and improve performance metrics.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    91 views19 pages

    ME RoTIC 2018 PresentationAbdulrahman Alkhowaiter Final

    Uploaded by

    Abdulrahman Alkhowaiter
    This document discusses several new technologies that can improve the reliability, safety, and efficiency of rotating equipment. It provides examples of implementing improved steam turbine designs with electronic trip systems and pneumatic actuators to achieve higher mean time between failures. Another example is retrofitting large steam turbines to replace hydraulic governor systems with electric actuators to eliminate failures from control oil systems. High-speed magnetic bearing compressors are also discussed as eliminating gearboxes, lubrication systems, and couplings for increased reliability. Overall the document argues that adopting new technologies can help prevent machinery failures and improve performance metrics.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 19

    Practical Implementation

    of New Rotating
    Equipment Technologies
    For Reliability, Safety,
    Efficiency
    tt

    By Abdulrahman Alkhowaiter
    Senior Consultant, Saudi Aramco
    Introduction: Examples of New Technologies Implementation For
    Improved Reliability, Safety, and Efficiency

    1. General Purpose Steam Turbines Improved design technologies achieve high reliability.
    2. Retrofitting Large Mechanical drive steam turbines with Electrical Governor valve actuators
    and elimination of Hydraulic Control Oil Systems.
    3. Self-Contained Steam Turbine Modular oil system for Trip Valves.
    4. High Speed Direct Drive Magnetic Bearing Motor-Gas Compressors eliminate Gearboxes,
    Lubrication systems, and Shaft Couplings.
    5. Variable speed screw instrument air compressors provide reliability and high efficiency.
    6. Direct Drive low speed fan motors eliminate Gearboxes, Couplings, and Lubrication Oil in
    Heat Exchangers and Cooling Towers.
    7. Retrofitting machinery of 25 KW to 2000 KW with Permanent Magnet Shaft couplings to
    replace conventional dry or lubricated types.
    8. Retrofitting Rubber Element Couplings with new technology Zero Maintenance Flexible
    Element couplings on Synchronous Motor Drives.
    Who Needs New Machinery Technologies, We are Doing Great
    So Far!…... Or Is There Room For Improvement

    • Gas Plant Boiler ID Fan Driven


    by 1100 KW Steam Turbine.
    The Steam Turbine had an
    overspeed incident during
    maintenance, and Reduction
    Gearbox and lube oil system
    were Catapulted into the Air in
    year 2001.
    • Many of the machinery failures
    faced by Rotating Equipment
    engineers are Design and
    Maintenance failures that can
    be prevented with improved
    technologies. This brings
    improved Reliability, increased
    Safety and higher Efficiency.
    Conventional API-611 General Purpose Steam Turbines Are
    Known For Low Reliability: Typical MTBF of 6 Months

    As Specified by Design Contractor 2010 Saudi Aramco STD Design Method


    Innovative GP Steam Turbine Standard : Eliminate Failures by
    Electronic Trip + Pneumatic Actuators + M-Seals
    New Innovative General Purpose Steam Turbines Eliminate
    Failures: Electronic Trip + Pneumatic Actuators + M-Seals
    API-611 STD Turbine 0.5 Years MTBF New 2012 Design 4.5 Year MTBF
    Large Steam Turbine Reliability: Control Oil Systems With
    Hydraulic Actuators Introduce Many Governing Failure Issues
    Hydraulic Actuator Failure Points Conventional Mechanical or STG Drive Unit
    Steam Turbine Governor Actuators: Electric Actuators Replace
    Hydraulic Servomotors & Control Oil Systems

    Electric Ball Screw


    Actuators replace the
    original turbine
    servomotor hydraulic
    governor valve Piston-
    Cylinder.
    Eliminates the use of
    turbine oil for turbine
    speed control purposes.
    but retains it for the
    trip-throttle valve. By
    further modifications,
    the complete control oil
    system can be
    eliminated with self
    contained Hydraulic
    Trip-Throttle valves.
    Eight 24 MW Steam Turbine-Compressor Trains: Shaft Driven
    Governor & Actuator Upgraded to Electric Actuators 2012

    Hydraulic Actuator & Governor: 1983-2011 Electric Actuator Retrofit: 2012-2013


    Turbine E-Trip Valve Self Contained Hydraulic Unit Eliminates
    Control Oil System: No Contamination, High MTBF
    Redundant Pumping Unit 23 MW Turbine Dual Inlet Valves Trip-Throttle Valve
    High Speed Direct Drive Compressor Trains: Magnetic Bearings
    Eliminate Gearboxes, Lubrication Systems, LS Coupling
    Medyan Gas Plant: Two New High Speed 12,500 RPM Motor
    Sales Gas-Propane Compressors Commissioned March-2018
    Mag Bearing Compressor With DGS Compressor-Motor-Coupling: 40% Reduction in Skid
    Hermetic Sealed Gas Compressors High Speed Canned Motor-
    Compressor: No Shaft Seal, Gearbox, Lubrication, Couplings

    Direct Drive Compressor Trains:


     Eliminates the lube oil system
     Eliminates Oil Coolers
     Eliminates the Gearbox
     Eliminates LS Coupling
     Reduced Alignment problems
    Hermetic Canned Motor Unit:
    Eliminates all Couplings, Dry Gas
    Seals, Increases site safety. 75%
    Reduction in plant footprint.
    Saudi Aramco has a 4.5 MW, 9000
    RPM Natural Gas Compression
    unit installed at Gosp Service since
    2015. Failed at factory test, then
    modified. Running well 3.0 years.
    Variable Speed Motor Instrument Air Screw Compressors: Direct
    Drive And Gearbox Type Commissioned March-2018

    Variable Speed VFD Drive Screw Units:


     Reduces yearly energy consumption by
    25% minimum.
     Eliminates Shaft Coupling [IR Models].
     Proportional Flow Control eliminates start-
    stopping thus reducing load on machinery.
     Reduced noise-vibration at lower speeds.
     Life Extension through lower speed and
    temperature.
     Two installations commissioned 2018.
    Hermetic High Speed Centrifugal Air
    Compressors With Magnetic Bearings:
    None available on market for Desert
    Ambient Conditions, but one model by
    Hanwa Techwin is under development, will
    be tested in 2019.
    New Direct Drive Cooling Tower & Air Coolers VSD Motors
    Eliminate: Gearboxes, Couplings, Lubrication Oil, Belts, Pulleys
    Conventional Motor-Coupling-Gearbox-Fan Modern Direct Drive Motor-Fan 2018
    Innovative Permanent Magnet Couplings Provide High Reliability
    by Reducing Vibration & Less Startup Shock

    Description:
    New Permanent Magnet Shaft
    Couplings Eliminate Conventional
    Bolted Couplings which require
    Alignment, Transfer vibration, and cause
    Reliability problems.
    Manufacturers: Magnadrive and
    Fluxdrive.
    Benefits:
    Two types available: Fixed speed and
    Variable Speed
    Improve Rotating Equipment
    reliability such as pumps, by proven
    35% to 65%.
    Enhance pumps, blower, fans
    efficiency by varying shaft speed
    without VFD drives.
    Reduce maintenance cost at plants
    Torsionally Damped Couplings For Synchrounous Motors: High
    Maintenance Rubber Block Couplings With Vibration
    21000 KW 1800 RPM Synchronous Motor High Maintenance Rubber Block Coupling

    • After completing all maintenance


    activates for K-002A Sales Gas
    Compressor Coupling
    Replacement, today @ 11:30 am
    the machine was started and
    loaded successfully with normal
    temperature and vibration
    parameters. The maximum
    vibration reading on motor inboard
    tag# 61VI804X is 1.7 Mils, wher the
    alarm reading is 3.5 Mils and the
    shutdown is 6 Mils.
    • The vibration reading before the
    coupling replacement was 4.7
    Mils, now after the replacement
    the vibration reading has
    improved to 1.7 Mils.
    Innovative Zero Maintenance Flexible Metal Coupling: Tuned
    Torsional Design Application Replaces Rubber Block Coupling
    Highly Engineered 21000 KW CCA Coupling Three Units Installed 2016: 1.0 Mills Vibration
    Final Point: Examples of Industry Failures & Constant
    Maintenance Means That New Technologies Are Needed

    Any Questions Please

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