Investigating Operational Problems

Many operations teams continue to live with problematic systems because they cannot accurately pinpoint the underlying cause of the problems. This can cause ongoing costs and missed targets.

But combining the post-mortem ability of SCADA/DCS historians with our dynamic simulation and surge analysis programs allows operators to better investigate problems. Two core approaches can be used; we can replay the event using the historian data as a starting point. Or we can investigate what-ifs and scenarios known to cause problems from past experience.

Both approaches are non-intrusive which allows continued operation whilst the problems are explored. They are also less expensive than living with problems and continuing to pay for the downtime and repairs.

Damage & Downtime

Downtime, poor capacity and low availability can hinder the successful operation of systems.

We have also seen a wide range of damage that is costly especially if it re-occurs, such as:

• Weld damage
• Valve innards being damaged
• Pipe movement
• Exchanger failures
• Air vents and vacuum breakers being damaged after first use
• NRV failure & leakage
• Pump Damage
• Compressor (surge and backward rotation) damage

All of these problems can be investigated without interrupting normal operations by simulating the events that led to the damage or shutdown.

Budgeting & Being Prepared

Some of our clients have now realised that investing in a model of their major systems is money well spent because it then allows them to quickly diagnose any problems when they occur. This fast reaction can prevent re-occurrences and minimises downtime.

Models for each system are built using an ongoing budget, so that they are ready and tested before they are needed. In years when budget is not spent on investigating problems we perform Performance Analysis and Condition Monitoring on the system to predict any problems and wear before it occurs.