Design Of A Condition Monitoring System (CMS) For A Gas Compressor Using Shell Bonny Terminal As A Case Study

Subcontracted Researcher & Field Electrical and Electronics Engineer, Shell Bonny Terminal, Nigeria— 2013

I served as a Hooks Electric subcontracted researcher and field electrical and electronics engineer at Shell Bonny Terminal, spearheading a groundbreaking project to design and construct a state-of-the-art software condition monitoring system (CMS) for a gas compressor. In addition to my technical responsibilities, I also took charge of integrating this innovative design into the existing SCADA (Supervisory Control and Data Acquisition) infrastructure of the plant.

Working collaboratively with a team of four talented engineers, I successfully managed and coordinated their efforts throughout the project. Together, we leveraged our collective expertise to develop and implement a fully functional software condition monitoring system. This collaborative approach ensured that our project benefitted from diverse perspectives and skill sets, leading to a comprehensive and robust solution.

Utilizing my proficiency in LabVIEW, C#, native C, Java and ActiveX library, I led the development of a cutting-edge data acquisition (DAQ) device for CM system. This device seamlessly captured sensor readings from the live gas compressor in real-time, while the systemic algorithm I designed skillfully tracked false alarms using fallback sensors. By monitoring critical parameters such as ambient and self-temperature, axial speed, vibration, inflow pressure, and outflow pressure, we were able to enhance the system's reliability and performance.

Furthermore, I effectively integrated the software condition monitoring system into the plant's existing SCADA infrastructure, ensuring seamless communication and compatibility with the overall plant monitoring and control system. This integration facilitated centralized data management and provided comprehensive insights into the gas compressor's operation, enabling proactive maintenance and efficient decision-making.

By successfully managing the team and overseeing the integration process, I ensured that our project aligned seamlessly with the plant's existing infrastructure, resulting in an optimized and harmonized system.

Through our collective efforts, we delivered a highly sophisticated and fully integrated software condition monitoring system that significantly improved the management and performance of the gas compressor at Shell Bonny Terminal.

I have curated all the resource files that will enable anyone replicate our work. This is shared under the CC-by-4 license.

The LabVIEW codes are documented in Work.zip file and all manuals and equipment specifications have been uploaded. I have created a test bench to help anyone quickly test the LabVIEW software in simulation mode. 

I have also provided a slide presentation that summarizes our work, including methodologies and results.