Operator Rounds

[refinerypumps]

This will probably only apply to those of you with experience as an end user. Has anyone had good experiences with an operator round program for equipment (pumps in particular) monitoring? If so how was the program run? and what equipment did you use to gather data?

The refinery I work at has a program for operators to gather vibration and temperatures on pumps weekly. Operators use a matrix vibration meter and fluke infrared temperature gun to gather data. Operators are asked to monitor vibration at the bearings and temperatures of the bearings and various points in order to monitor seal flush plans for issues.
Operators then enter the data into handhelds which checks it against preset alarms. If there are vibration alarms the vibration analysts uses their much more sophisticated CSI vibration analysis machines to check the equipment. If there are temperature alarms an engineer or foreman will verify the issue and generate a work order to correct it hopefully before the seal fails.

The program is good in theory but the data is not good which ruins the program. The vibration pens are inaccurate and generate mostly false alarms. The infrared temperature guns are awful for measuring small bore piping especially when it is rushed. Does anyone have a better method or equipment to use?

Thanks in advance.

 

[1gibson]

For the IR temp gun, they can have problems with emissivity on smooth metallic surfaces, paint a black patch or put on some black tape. This will also ensure the reading it taken in the same place each time, with every operator.

 

[refinerypumps]

Yes we did have that issue initally but have corrected it. Our primary issue now is picking up things in the background when trying to measure tubing / small bore piping due to the area the IR gun measures. This can be corrected by holding paper or a glove behind what you are measuring and scanning over it and taking the temperature when it changes, but getting operators to do that has been difficult.

I'd like to get some sort of simple contact based temperature measurement but havent found anything.

 

[1gibson]

What temps are you talking? Search McMaster for "temperature indicating labels." Great for putting on stainless tubing or small pipe, and you can't beat the price.

 

[refinerypumps]

Temperatures are around orifices and coolers on API flush plans to check that the seal is getting flushed properly. For example on a plan 11 flush an operator should check the temperature on the upstream and downstream side of the orifice if they vary significantly the orifice is clogged and should be removed and cleaned.

 

[itsmoked]

How about something like this where they're so cheap they can be installed everywhere you want the temp and the readings will be consistent because they'll always be taken from the exact same spot. If you need the differential, use two of them. You could probably even get them at a bulk price.


digital-compact-lcd-thermometer-with-outdoors-remote-sensor



Keith Cress
kcress -

http://www.flaminsystems.com

 

[refinerypumps]

They would need to be Class 1 Div 2 rated which would drive up the price very fast I am sure. Sorry I keep adding constraints.

 

[KMenges]

A couple suggestions from a pump OEM.
Could you install temperature gauges in your seal piping and have the operators record those readings instead?
Also, the IR handhelds vary widely in terms of spot sizes, more expensive hand helds generally have a a tighter spot size. For critical applications like shooting steam trap from far away the typical fluke meters can't cut it. Look at the models available from Raytek which should be available C1D2.

Hope this helps.