© Howden Group 2019

Contents

1 Revolving around you

2 Digital Twin

3 Data capturing & connectivity

4 From data to added value

5 Uptime hardware reciprocating compressor

6 Performance monitoring using a digital twin

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 Revolving around you

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 Digital Twin
• In-depth asset analytics
• Predictive analytics
• Data driven analytics
• Model driven analytics

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 Digital Twin
In-depth asset analytics

Digital Twin
• Core of the Uptime digital solution portfolio, driven by Howden’s domain knowledge and
built on world leading Industrial IoT solutions
• Dynamic link between real-time performance data and physics-based model
• The physics based model does not rely on the existence of historical data, nor is it
conditioned by the data quality
Detecting rotating equipment failure before it occurs
Process data

Design data and identifying the root cause

Operational data
Understanding the impact of change in operating
conditions on the equipment and process performance

Moving critical equipment maintenance strategies from

reactive to full predictive
Time

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 Digital Twin
Predictive analytics

Asset Types Digital Twin types

• Homogeneous
– Identical assets
– Identical environment
• Heterogeneous
– Similar but not identical assets
– Varying environments
• Data-driven
– Requires data
– Less complex, limited applicability
• Model-driven
– Requires domain knowledge
– More complex, broader applicability

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 Digital Twin
Data-driven analytics
Unsupervised Learning
• Learns general rule to detect presence or
absence of commonality in analyzed data
• Anomaly detection, outlier detection
• No training data required
• Accuracy vs. sensitivity
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Supervised Learning
• Learns general rule to map input to output
• Image recognition, speech recognition,
handwriting recognition
• Training data required; uses labeled datasets
• Applicable for homogenous applications
 Digital Twin
Model-driven analytics

Physics-based Digital Twin

• Thermodynamics, equations of state
• Asset agnostic core, so applicable on both Howden
and non-Howden assets

Self learning
• Real-time coupling to sensor data
• Continuously mirroring the virtual asset replication

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 Data capturing & connectivity
• A brief introduction of the data journey

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 Data capturing & connectivity
The Data Journey

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 From data to added value
• Goal
• Focus
• Uptime portal

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 From data to added value
Goal
120

Uptim e automated alert

Digital twin health indicator (%) 100

Failure / MPS trip

80

Condition monitoring alarm

60

40

Norm al operating Predictive action window

w indow
20

0
Time
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 From data to added value
Focus

Cylinder Cylinder Crosshead

Rod drop
pressure acceleration acceleration

Valve leakages ◼ ◼

Valve failures ◼ ◼

Piston ring wear ◼

Rider ring wear ◼ ◼

Maintenance & failure Piston rod packing wear ◼
modes Crosshead pin & bushing clearance & lubrication ◼ ◼

Crosshead shoe clearance & lubrication ◼ ◼

Rod load & reversal ◼ ◼

Mechanical assembly issues, static and rotating parts ◼ ◼ ◼ ◼

Power consumption & losses improvement ◼

Wear parts lifetime improvement ◼

Performance optimization
Compressor flow & load optimization ◼

Process & controls optimization ◼

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 From data to added value
Uptime portal

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 Howden Uptime hardware
Reciprocating compressor

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 System Architecture
Stand alone system

Power supply

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 Components & Instruments
sensors ATEX Zone 1 IIC

❑ Accelerometer
Crosshead and cylinder vibration
measurement

❑ Pressure Transducer
In-cylinder pressure measurement

❑ Rod Drop probe

Vertical piston rod position measurement

❑ Keyphasor
Crank-angle reference signal

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 Components & Instruments

❑ Single enclosure
ATEX Zone 1 IIC compliant
Data capturing and analysis in real-
time
High-frequency 60kHz sampling of
inputs, synchronized to crank-angle
position
FFT (Fast Fourier Transform) frequency
analysis
Dell Edge processing

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 Components and instruments
Howden 19inch rack – BN 3500 rack

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 Performance monitoring using a
digital twin
Actuator failure reciprocating compressor

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 Reliability Energy Savings Trusted Advisor
Reduce unplanned Optimize equipment, Supports proactive
downtime by predicting process and plant maintenance strategies
failure before it happens, performance resulting in tailored to equipment
reducing maintenance substantial energy savings needs with direct link to
costs and extending and reducing Howden product experts
outage intervals environmental impact

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 Any questions?

© Howden Group 2020