OIL & GAS
Because the Artesis system is simple to install and requires little user intervention in operation, it combines low start-up costs with the significant benefits of predictive maintenance. Since it doesn’t require any sensor installation on the equipment itself, and it can be installed in non-EX areas, Artesis eMCM is a particularly good solution for inaccessible equipment in the oil and gas industry.
Typical applications where you can monitor either electrical, mechanical and water pumping conditions:
Around 60% of the electric motors used in the oil and gas industry are used to drive pumping systems, being well pumping an essential upstream activity in the industry.
Monitor all motors connected to the different pumps in your wells to control the mechanical and electrical conditions at any time and without the need to reach hazardous and remote areas. In addition, you will be able to monitor the mud pumps of your drilling rigs to make sure the drilling process is properly completed.
With a continuous monitoring of these conditions Artesis technology is able to prevent you from stopping any well operation due to imbalance, misalignment, bearing damage or any other possible mechanical or electrical problem that may come up in the electric motors of your well pumping systems.
When it comes to downstream activities in the oil and gas industry, refining is at the top of the list. Here electric motors can be found in every step of the refining process, making for a huge number of them, thus complicating regular condition monitoring processes. By using Artesis technology you will reduce the time and labor to conduct a proper condition monitoring process.
Monitor your Fluid Catalytic Unit (FCC) also known as the “cat cracker”, consider the heart of the refinery, without the need of installing any expensive sensors that may (or may not) withstand the higher temperatures generated in this process.
Some other important steps where Artesis technology can be very useful are Sulfur Recovery, Distillation, Water Treatment, Alkylation, among others where pumps, compressors, and fans are essential.
In addition, with the Artesis technology, you will be able to, without much effort, monitor all air compressors, fans, and other rotating equipment driven by electric motors which are numerous in any refining facility.
All types of drilling rigs (fixed, compliant towers, floating, drillships, tension-let, subsea systems, sea-star, spar) are autonomous in energy and water needs, housing electrical generation, water declinators and all of the machinery to process oil and gas in a way that it can be either delivered directly onshore by pipeline or to a floating storage unit or tanker loading facility.
However, there are many risks due to the extraction of volatile substances under extreme pressure in a hostile environment.
Artesis technology can detect machinery problems far before they become a tragedy. Drilling machines, draw works, mud pumps, sheaves, and thrusters can be monitored continuously without installing sensors in hazardous areas.
The liquefaction process requires machinery working under extreme conditions. Reciprocating compressors used for low-temperature refrigerant in the liquefaction process can be continuously monitored by Artesis technology as well as gas turbines, and cryogenic pumps.
ROI Case of a Propane Compressor
ROI calculations are made for the K-1453 Propane Compressor monitored in an oil refinery. The CCR Unit’s Screw Type Propane Compressor started to give alarm from MCM system as shown in the figure below. This alarm is also verified by vibration monitoring as well.
The refinery’s rotating equipment team had decided to shut down the machine and repair it. After disassembling of the equipment, the bearing fault and the damage on the windings of the motor due to the burned grease on them were observed as seen in the figure below.
Following the diagnosis, motor and the compressor had been repaired; all bearings, gaskets, and O-rings were changed, windings were checked and cleaned. This maintenance activity had taken 3 days and the compressor had restarted again. The total cost of this maintenance was €23,000.
If this fault was not determined using the predictive maintenance approach such as MCM system the failure consequence could be worse and the total cost could increase dramatically as estimated below:
- The motor could burn: Total cost of rewinding would be €24,000
- General overhaul of the compressor (changing casing, rotors, etc.): Total cost of the overhaul would be €123,000
- Due to reduced throughput: Rewinding of a 440 KW motor could take 20 days. The daily loss of reduced throughput (100 m3/day) roughly 9,000 (90 €/m3). For 20 days total production loss would be €180,000
Finally, in the worst-case scenario, the total cost of maintenance would be €327,000.