MORP Quadrant
Maintenance, Optimisation, and Rationalisation Program
The 4 Cornerstones of Condition Monitoring
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MORP Overview
As assets approach the end of their life, an AJSS Maintenance Optimisation and Rationalisation Program (MORP) is designed to reduce maintenance costs whilst trying to extend asset life and utilisation. MORP involves a detailed assessment of existing maintenance practices, benchmarking with industry and providing AJSS maintenance and technology recommendations to drive cost savings.
Equipment Life Cycle
Initially, the OEM's are most involved with newly installed equipment. As the project approaches the end-of-life, OEM reliance decreases, and in-house knowledge is accumulated.
Key Equipment Phases
When equipment is first installed, large oil and gas companies are risk averse, and thus hesitant to step away from Original Equipment Manufacturers (OEMs). In this first phase this makes absolute sense. Less familiarity with the installed machinery, and their operating environment make manufacturer guarantees and warranties attractive. Here, a less riskier but expensive process, budgeted for in a field study is anticipated.
After familiarisation with the equipment and its operating conditions, less focus is placed on the OEMs, which are generally relegated to an ad hoc support role. Moreover, maintenance is carried out by in-house teams. During this stage production is at a maximum resulting in cost not being a major concern.
When the project moves towards its end-of-life. Here smaller engineering businesses optimize technical and operational procedures to reduce costs, including environmental ones such as the carbon footprint.
Concepts that can be implemented to achieve this include:
- •Circularisation
- •MORP
Preventative & Predictive Maintenance
Both Preventative and Predictive maintenance are proactive approaches attempting to resolve issues before a failure occurs.
Preventative Maintenance
Where maintenance is scheduled on a time-basis. Whilst this may initially be great for planning, many failures occur unexpectedly, and this method can result in either under- or over-maintenance. It is well suited for recurring/frequent problems, or if asset value is low.
Predictive Maintenance
Utilises collected data (usually from sensors) to identify and address issues as they occur. Obstacles to predictive maintenance include the complexity, training, and data required. It is utilized when chance of unexpected failure is high and would have a major impact on the business.
MORP Engagement Process with the Client
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Results of MORP
MORP results in more streamlined technical and operational procedures. This results in savings associated with maintenance.
MORP together with circularisation:
Extends Life of Equipment Far Beyond OEM Life Expectancy
Minimises Cost
Reduces Risks
Maximises Efficiency
This results in:
Increased Lifecycle Value
Decreased Lifecycle Cost
Performance Monitoring
Gas Turbine Performance monitoring using package-installed instruments is crucial for identifying how well the engine is operating. When performance drops, it can be a sign of issues within the system. By tracking performance, certain problems can be mitigated before complete failure, and efficiency losses can be restored.
Performance Curves
Performance curves provided by the manufacturer display how well equipment should be performing. The curves are based on monitored parameters including: key temperatures, pressures, flow rates, shaft speeds, etc. The parameters observed will vary depending on the turbine engine model.
Recoverable vs Non-Recoverable
Throughout the engine operation, certain performance losses cannot be restored. These are dubbed "Non-Recoverable". The only means of restoring the engine performance in this case is to undertake a shop inspection and engine overhaul.
On the other hand, "Recoverable" losses can be restored through gas turbine cleaning, which includes online and offline water and detergent washing.
A graph showing the temperature increases and Compressor Discharge Pressure (Pcd) losses over time. Some of these losses are recoverable, whilst others are not.
Causes of Performance Degradation
- •Compressor Fouling
- •Engine Air Leaks – Bleed Valve, Case Leaks, Shaft Seals, Engine Seals
- •T5 Spread Changes – injector fouling, injector replacement, combustor distress
- •Increased blade tip clearances – compressor or turbine
- •Output Power Measurement errors
- •Inlet Filter Fouling
- •Elevated exhaust back pressure
- •Variable Guide Vane setup – GV lockup, GV linkages broken, changed or modified
Why Perform Borescoping?
Borescoping is used to view hard to view/access areas within a gas turbine engine. This is critical for identifying whether interior damage has occurred to the engine. It is a non-destructive maintenance technique, which can assist with early detection of issues - before identified by the sensors. Additionally, previous images and videos obtained different inspections are employed to track changes in engine components. Overall, borescoping prevents the need for engine disassembly, saving resources used for scheduled downtime and maintenance.
Borescoping may be undertaken if abnormal conditions are observed, including:
- •Increased Vibrations
- •Unexpected Performance Drop
- •Abnormal Sound Patterns
- •Excessive Emissions
Borescoping Images
The formation of a mid-level crack.
Types of Borescopes
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Tip Selection Considerations
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Why Perform Vibration Analysis?
Vibration Analysis is a key non-intrusive strategy to ensuring health of equipment, and identifying issues before a failure causing unscheduled downtime occurs. It involves analyzing movement relative to source (vibrations). Through this strategy, the lifespan of equipment can be extended, and the chance of unscheduled downtime reduced.
Vibration monitoring can detect:
- •Poor maintenance practices including: improper bearing installation and replacement, inaccurate shaft alignment or imprecise rotor balancing
- •Mechanical Issues including: looseness, rubbing, bent shafts or cracked gears
- •Bearing Defects
- •Operational issues including: cavitation, flow issues, aerodynamic forces
Types of Vibration Sensors
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Methods of Vibration Analysis
Waveform Plots are represented in the time domain.
Why Perform Oil Analysis?
Oil analysis is a key aspect of monitoring machinery health - acting as a warning of imminent breakdown, and can also identify the oil condition. Throughout these tests, three main factors are assessed:
- •The Lubricant Quality - typically through additive depletion and oxidation
- •Extent of Machinery Wear - through the ferrous content in the oil
- •Contamination - Which can result from the environment or machinery
Types of Tests
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Types of Tests Undertaken
- •Screening: Assesses equipment for potential issues, often on non-critical or suspected problem areas. It offers quick results without the expense of full-slate oil analyses.
- •Predictive: Utilized for equipment with low-replacement costs or criticality.
- •Proactive: Performed on newer, more expensive equipment, which is more critical to the system functionality.