PREVENTIVE MAINTENANCE PROGRAM AND NOVEL TECHNIQUES TO REDUCE DOWNTIME AND INCREASE OPERATING EFFICIENCY AT DISTRIBUTED COGENERATION FACILITIES

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1 IDEA 2013 February, San Diego PREVENTIVE MAINTENANCE PROGRAM AND NOVEL TECHNIQUES TO REDUCE DOWNTIME AND INCREASE OPERATING EFFICIENCY AT DISTRIBUTED COGENERATION FACILITIES Dorin Scheianu and Tom Le Wood Group GTS, Houston 0

2 IDEA 2013 February, San Diego SUMMARY Gas Turbine Maintenance Total Plant Service Optimization Concept Case study: Turbine Upgrade - Rady Children s Hospital (San Diego) Case study: Turbine Analysis Tools - Rice University (Houston) Preventive maintenance and data analysis designated to better diagnosing turbine condition and planning term maintenance services 1

3 IDEA 2013 February, San Diego PURPOSE OF GAS TURBINE MAINTENANCE Maintain plant availability, reliability and component life expectancy Maintain plant performance (power and specific fuel consumption) Maintain optimal tuning Keeping compliance with applicable regulations Keeping all possible operating options for the owner Allowing for applicable hardware (including turbine) and software upgrades for safety, reliability and performance Allowing analysis of operation with the purpose of continuously improving plant parameters 2

4 IDEA 2013 February, San Diego TOTAL PLANT SERVICE OPTIMIZATION CONCEPT A SERVICE PROVIDER S AGENDA Mobilization and Operational Services Site inventory Site Systems Manuals and Training Operational Procedures Manual Computerized maintenance management system Administrative procedures program Operator qualification program Additional services 3

5 IDEA 2013 February, San Diego Case Study - RADY CHILDREN S HOSPITAL FACILITY SUMMARY DTE Energy San Diego, LLC. established to provide O&M services to Rady Children s Hospital of San Diego. Rady Children's Hospital-San Diego is the region s pediatric medical center serving San Diego, Imperial, and southern Riverside counties. 4

6 IDEA Conference Rady Children s Hospital RADY CHILDREN S HOSPITAL The largest children's hospital in California (based on admissions) The sixth largest children's hospital in the country The only hospital in the San Diego area dedicated exclusively to pediatric healthcare The region's only designated pediatric trauma center Provider of care to more than 82 percent of the region s children Provider of care to more than 150,000 children in 2011 Outstanding team includes nearly 700 physicians and more than 1,000 nurses, nearly 4,000 employees, 450 active volunteers, and more than 1,200 auxiliary members. 5

7 The Project DRIVERS FOR PROJECT DEVELOPMENT New facility commissioned in 2011, demanding additional power and heat New hospital equipment requiring sudden excursions in power of 700 kw Need for reliable and uninterrupted power (35+ life saving surgeries performed daily, out of a total of 200+) Need for margin to max load, to ensure uninterrupted operation Need for process efficiency Compatibility with the existing equipment and installations already the boiler and subsequent cogeneration existing with no intent to be replaced) Short time for completion, involving all of the following: Mechanical installation Electrical installation and controls changeover Specific auxiliary equipment changeover Tests and commissioning Long term service contract with service provider 6

8 The Project PROJECT SCOPE Replacement of the existing gas turbine Centaur 40 with a Taurus 60 Replacement of main reduction gearbox Replacement of control software Maintaining the existing electric generator Maintaining the existing skid Maintaining the existing electrical installation Making all mechanical and electrical adaptations Addition of an acoustics monitoring system for the new combustor Commissioning the new turbine Addition of a remote control access system (under development) 7

9 Equipment Layout Exhaust gas 860F Hot Water 400 F Absorption cycle Chilled water 33 F Natural Gas Steam 76 psig 8

10 Project Overview PROJECT SUMMARY One (1) Solar gas fueled turbine generator package This unit was purchased new with a Centaur 40S turbine engine and commissioned by Solar Turbines in Turbine Generator package was upgraded by Wood Group to T7901S turbine engine in August Specification Centaur 40 Taurus 60 Engine ID T4701S T7901S Serial No. OHJ08 C0841 N/A ISO Power (G) 3516 kwe 5513 kwe NGP (RPM) Hz Hz IGV Setting +8.0 DEG +7.0 T5 Base (G) 1104F 1290F T5 Set Point (G) T5 1170F T5 1250F Emission SP (G) 1132F 1230F % Pilot (G) Part Load 3 4 % Pilot (G/L) Full Load 2 3 9

11 Project Execution TIMELINE FOR EXECUTION Removal & Installation Start Date Testing, commissioning and Hand Over Date Total Duration August 3 rd, 2012 August 9 th, Days Centaur 40 Performance Generation Power: 3516 kw rated / 2800 kw typical, no capability for sudden excursions in power demand Exhaust Temp: 860F quasi constant Heat Recovery Primary Production: Hot water 400 F Secondary usage of recovered heat: steam 76 psig, cold water 33 deg. F Low Emissions Taurus 60 Performance Generation Power: 5513 kw ISO rated, 3200 kw typical with sudden excursions up to 4700 kw Exhaust Temp: 960F quasi const. Heat Recovery Primary Production: Hot water 400 F Secondary usage of recovered heat: steam 76 psig, cold water 33 deg. F Low Emissions 10

12 Project Execution New turbine after installation 11

13 Turbine Up-Rate Benefits OPERATIONS & MAINTENANCE COSTS AND BENEFITS Centaur 40 to Taurus 60 Conversion No change in operating and management costs Rated power: increase by 57% Typical operating power: increase from 2800 kw to 3200 kw Maintenance Cost: increase of service contract fee by 33% Fuel Cost per kw: reduction, due to better efficiency Heat recuperated: better quality, due to higher exhaust temperature. Actual operation of new turbine ensures quasi constant exhaust temperature at variable exhaust flow. New operation is perceived as ensuring an increase in hot water production. Total blackouts were eliminated 12

14 Remote Monitoring REMOTE CONTROL ACCESS, MONITORING AND DIAGNOSIS Part of a quality long term service agreement Monitoring early changes of equipment health indices and supplying proper maintenance as deemed necessary Monthly (typical), weekly or daily (if needed) turbine health monitoring reports Better scoping and planning of next scheduled term maintenance Additional help when solicited Optional help from the service provider, when opportune Remote tuning of control parameters, when such service is appropriate 13

15 Analysis Tools SPECIFIC SITE CONDITIONS-AMBIENT TEMPERATURE % operating time 35% 30% 25% 20% 15% 10% 5% 0% 25% % of oeprating time 20% 15% 10% 5% 0% T1 ambient, histogram, Rice Deg. F ambient T1 ambient, Rady Ambient temperature T1, deg. F % operating time T1 histogram, Unit 1 and T1 ambient, Deg. F Ambient temperature profile is site specific and extremely well differentiated 14

16 Analysis Tools 30% 25% MONITORING DATA Histogram, Output power, Rice Histogram, output power, Ref. Unit 1 20% % operating time 20% 15% 10% 5% 0% kw % operating time 15% 10% 5% 0% kwe Operating profile depends of many objective and subjective factors Unit 1 and Unit 2 although identical and in parallel, have different operating profiles % operating time 14% 12% 10% 8% 6% 4% 2% 0% Histogram, output power, Ref. Unit kwe 15

17 Analysis Tools Generator output, kw kwe vs. T1, all data, Rice T1 ambient, deg. F MONITORING DATA kwe kwe vs. T1, all data, Ref. Unit T1 amb, deg. C Typical indicators: kwe, CDP, SCF, TTex Each regressed at baseload (function of T1) or at any load (function of T1 and % command) Deviations actual to expected matched to most common faults Appropriate maintenance scoped and scheduled at nearest term service kwe kwe vs. T1, all data, Ref. Unit deg. C 16

18 Analysis Tools PCD, psig CDP vs. T1, all data, Rice T1 ambient, deg. F MONITORING DATA PCD, kpa CDP vs. T1, all data, Ref. Unit Ti ambient, deg. C CDP is a direct health indicator for turbine compressor It is well known that periodic service is required It is also related to the air inlet filter house Easier to assess baseload data, more complex based on all data kpa CDP vs. T1, all data, Ref. Unit deg. C

19 Analysis Tools kwe actual / kwe expected MONITORING DATA kw ratio, Rice Univ. kw ratio baseload, Ref. Unit kw Ratio 0.6 9/14/2011 1/12/2012 5/11/2012 Date 9/8/2012 1/6/2013 kwe, actual/expected /1/2012 4/2/2012 Date 6/2/2012 8/2/ T amb deg. C 1.05 kwratio base load, Ref. Unit 1 Ratio of kw actual / kw expected at baseload makes easy to assess significant changes in engine performance and helps reveal possible causes kwe, actual/expected /1/12 3/31/12 Date 6/29/12 9/27/12 18

20 kwe Analysis Tools kwe vs. T1, base load, Rice Univ. MONITORING DATA y = 21x T1 ambient, deg. F kwe kwe vs. T1, base load, Ref. Unit 1 y = x T1 amb, deg. C kwe kwe vs. T1 at base load, Ref. Unit y = x T amb, deg. C Regression of parameters at baseload vs. ambient temperature Regression parameters are specific to each turbine Differentiation of effects kw as overall parameter, CDP, TTex, T5 spread and SFC allow differentiation between turbine components 19

21 lysis Tools DP ratio and kw ratio, Rice Univ. PCD Ratio kw Ratio /12/2012 5/11/2012 Date 9/8/2012 1/6/2013 MONITORING DATA kw actual / kw expected PCD ratio CDP Ratio and kw, all data, Rice PCD Ratio kw /1/11 11/1/11 2/1/12 5/3/12 8/3/12 11/3/12 2/3/13 Date Generator output, kw CDP ratio and TTex, Ref. Unit /22/2012 5/11/2012 6/30/2012 8/19/2012 Date Deg. C PCD, actual to expected 1 CDP ratio and TTex, Ref. Unit T /1/12 4/10/12 Date 7/19/12 10/27/12 T5, T7 deg. C

22 lysis Tools SFC, Btu/kW HR, Rice MONITORING DATA Generator output, kw Btu/kW HR SFC, Baseload, Rice y = x x Generator output, kw SFC Baseload T1, Rice y = x Ti ambient, deg. F Specific Fuel Consumption is extremely sensitive to any degradation occurring inside the turbine Care should be taken to consider effects of load change besides ambient temperature

23 A 2013, February, San Diego APPLYING TECHNICAL EXPERTISE AND SKILLS AT SCHEDULED TERM MAINTENANCE AND BETWEEN INTERVALS BY REMOTE MONITORING Borescope inspections Vibrations data collection and analysis Remote monitoring and real time performance analysis, with real time plot of multiple engine health indicators Combustion Dynamics monitoring and automatic corrective actions Periodic maintenance

24 A 2013, February, San Diego CONCLUSIONS s turbine maintenance is a key service to providing steady performances, high ailability and reliability for the equipment. As important as initial design and bsequent upgrades tal plant optimization concept se study: Turbine upgrade - Rady Children s Hospital (San Diego) cogeneration ility se study: Turbine analysis tools - Rice University (Houston) eventive maintenance and analysis designated to better planning term intenance services. Daily, weekly and monthly visual reports generated tomatically.