gas turbine & compressor

operations & maintenance solutions

Managing Fleet Performance

Sikobe Litaba - Technical Manager, Cogsys Ltd
8th Annual Industrial & Power Gas Turbine O&M Conference
20th - 21st November 2002 London
 Managing Fleet Performance

who are we?

capital replacement strategy

emissions reporting, reliability analysis

varied applications for diverse fleets

performance assessment principles

combined gas turbine & process compressor performance

 Who are we? - Group Organisation

National Grid Transco plc

Transco Advantica Technology

3m
business unit
product performance monitoring software products &
investment engineering teams for gas turbines & compressors
Cogsys Limited
established 1990
 ISO corrections

all performance data is ISO

corrected and compared
with a fingerprint of the
engine

deviations from expected

performance trigger
diagnostics tools to enable
rapid, preventative action
 Gas Turbine - baseline analysis

Actual performance
points

Baseline performance
lines

ABC Mode

AB Mode

Change burner mode

BC Mode to BC to save fuel if
demand is unlikely to
increase

Shows a fuel issue for

BC mode in this case -
LM2500+DLE : Fuel flow (NTI) vs combuster inlet T can then drill down to
determine whether
mechanical or control
Gas Compressor - baseline analysis

AB Mode

BC Mode
 Model Based Diagnostics - principles

Actual Process

Process
Plant
Outputs

Process Root
Discrepancies
Inputs Cause

ALERT Predicted
Models Outputs

Rigorous Thermodynamic Modelling for Gas Turbines & Compressors

Quickly eliminate spurious data (e.g. sensor errors)

Determine un-measured values (e.g. hot section gas path)
Gas Turbine - Model Based Diagnostics
RB211-24C gas path analysis

actual process data is

compared with modelled
values along the gas path

sensor errors are quickly

eliminated by comparison
with modelled values

un-measured values are

determined in the hot zone
to support component life
prediction

fault indices are produced

enabling diagnosis at the
component level
 Gas Compressor -
Model Based Diagnostics

polytropic efficiency and

head coefficients are
modelled

gas turbine driver

characteristics are
deviations from the models displayed on the
enable possible sensor compressor envelope
errors to be eliminated
leading to rapid
fault diagnosis
 On Line Instrument Validation
healthy discharge temp, spurious efficiency
 On Line Instrument Validation
healthy efficiency, spurious suction temperature
 Fleet Performance Applications
varied applications for diverse fleets

Offshore Gas Injection

(Peak Storage)
Onshore Pipeline
Transmission LTSA - Remote Monitoring
(Transco UK grid) (Independent Healthcare)

Offshore Gas Production

(UK Continental Shelf)
European Interconnector
(UK- Belgium)

Onshore Power Generation

and CHP (France) Acceptance Testing
(Overhaul & Repair)

NGL Gas Processing

 Remote Management of Fleets
validated centralised data & optimised resources

on-shore off-shore power

compression compression plant

A B C A B C A B

service centre

out-sourced
maintenance / service
provider
Operations
control room
 Fleet Emissions Management
validated monitoring & reporting using performance data

emissions
fingerprint + engine
parameters + process
conditions
calculated
emissions

fuel flow, exhaust T
fuel specific gravity

mechanical condition
fuel calorific value

AIT, CDP, CDT, etc..
etc..

IPPC regulatory approval

fleet wide solution enabling emissions trading

reduced capital investment & maintenance costs

 Fleet Emissions Management
engine model specific validation and characterisation - SAC
 Fleet Emissions Management
Engine model specific validation and characterisation - DLN

Typical GE LM2500+DLE Gas Turbine - NOx emission profile

OCMS NOx Primary Bulk Reference Baseline - All Modes (variable bleed range 50% TFL) @ 15% O2 Ref.
y = -4.76857E-01x + 2.34661E+02 y = 5.87267E-03x 2 - 5.25563E+00x + 1.20453E+03
y = -2.71533E-03x 2 + 1.63574E+00x - 1.83720E+02 y = -4.82959E-01x + 2.31191E+02
100
EA Site Authorisation Limit Full Load Rating 27.4 MW @ 470 T3SEL

75% of Rating 20.5 MW @ 425 T3SEL

90
Push
50% of Rating 13.7 MW @ 385 T3SEL
Authorisation limit
80
NOx-PRI (AB check 1)

burner modes BC to AB
70
NOx-PRI (AB check 2) to ABC
NOx-PRI (ABC check)
NOx-PRI (BC check)

Note NOX emissions
NOX _P RI (m g/m ^ 3)

60
BC Push NOx-CONC (BC push) increase at end of each
50
NOx-CONC (AB push 1)
burner mode -
Push NOx-CONC (AB push 2)
NOx-CONC (ABC push) minimum bleed push
40
AB Linear (NOx-PRI (AB check 1))
Linear (NOx-PRI (AB check 2))
30
ABC Poly. (NOx-PRI (ABC check))
Poly. (NOx-PRI (BC check))
20

10

0
260 280 300 320 340 360 380 400 420 440 460 480 500
T3SEL (Deg C)

GE LM2500+DLE : NOx vs combuster inlet T

 Fleet Reliability Management
engine component life - low cycle fatigue

Implementation of OEM
bulletin recommendations

Calculation of cyclic usage

between stop / start cycles
& over engine life

Particularly useful in
variable load applications

Cost-effectively schedule
component replacement
particularly in hot section

RR Avon Mk.1533 : Gas Generator - Low Cycle Fatigue

 Fleet Reliability Management
standard station/unit alarm & trip categorisation
 Fleet Capital Replacement Strategy
based on Performance, Emissions, Availability & Reliability data
Fleet Capital Replacement Strategy
multiple criteria decision analysis
Fleet Capital Replacement Strategy
multiple criteria decision analysis
 Summary

OEM independent

capital replacement strategy

emissions reporting, reliability analysis

diverse fleet and industry applications

performance assessment principles

combined gas turbine & process compressor performance

 gas turbine & compressor
operations & maintenance solutions

Cogsys Limited
Tel. +44 (0)161 868 4450
info@turbo-alert.com
www.turbo-alert.com