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
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
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
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
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
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
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
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
Equipment Layout Exhaust gas 860F Hot Water 400 F Absorption cycle Chilled water 33 F Natural Gas Steam 76 psig 8
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 2002. Turbine Generator package was upgraded by Wood Group to T7901S turbine engine in August 2012. Specification Centaur 40 Taurus 60 Engine ID T4701S T7901S Serial No. OHJ08 C0841 N/A ISO Power (G) 3516 kwe 5513 kwe NGP (RPM) 14951 60 Hz 14951 60Hz IGV Setting +8.0 DEG +7.0 DEG @59F 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
Project Execution TIMELINE FOR EXECUTION Removal & Installation Start Date Testing, commissioning and Hand Over Date Total Duration August 3 rd, 2012 August 9 th, 2012 6 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
Project Execution New turbine after installation 11
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
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
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 40 50 60 70 80 90 100 110 120 Deg. F ambient T1 ambient, Rady 35 40 45 50 55 60 65 70 75 80 85 90 95 Ambient temperature T1, deg. F % operating time 0.25 0.2 0.15 0.1 0.05 0 T1 histogram, Unit 1 and 2 4 5 14 23 32 41 50 59 68 77 86 95 104 T1 ambient, Deg. F Ambient temperature profile is site specific and extremely well differentiated 14
Analysis Tools 30% 25% MONITORING DATA Histogram, Output power, Rice Histogram, output power, Ref. Unit 1 20% % operating time 20% 15% 10% 5% 0% 2500 2700 2900 3100 3300 3500 3700 3900 4100 4300 4500 kw % operating time 15% 10% 5% 0% 3100 3300 3500 3700 3900 4100 4300 4500 4700 4900 5100 5300 5500 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 2 25002700290031003300350037003900410043004500470049005100 kwe 15
Analysis Tools Generator output, kw 5000 4500 4000 3500 3000 2500 2000 1500 1000 kwe vs. T1, all data, Rice 20 40 60 80 100 120 T1 ambient, deg. F MONITORING DATA kwe 6000 5500 5000 4500 4000 kwe vs. T1, all data, Ref. Unit 1 3500 3000 2500 2000 20 10 0 10 20 30 40 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 6000 5000 kwe 4000 3000 kwe vs. T1, all data, Ref. Unit 2 2000 1000 20 10 0 10 20 30 40 deg. C 16
Analysis Tools PCD, psig 140 130 120 110 100 90 CDP vs. T1, all data, Rice 20 40 60 80 100 120 T1 ambient, deg. F MONITORING DATA PCD, kpa CDP vs. T1, all data, Ref. Unit 1 1300 1200 1100 1000 900 800 700 600 20 10 0 10 20 30 40 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 1300 1200 1100 kpa 1000 900 CDP vs. T1, all data, Ref. Unit 2 800 700 600 20 10 0 deg. C 10 20 30 40 17
Analysis Tools kwe actual / kwe expected MONITORING DATA kw ratio, Rice Univ. kw ratio baseload, Ref. Unit 2 1.2 1.1 1 0.9 0.8 0.7 kw Ratio 0.6 9/14/2011 1/12/2012 5/11/2012 Date 9/8/2012 1/6/2013 kwe, actual/expected 1.2 1.15 1.1 1.05 1 0.95 0.9 0.85 0.8 2/1/2012 4/2/2012 Date 6/2/2012 8/2/2012 50 30 10 10 30 50 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 0.95 0.9 0.85 0.8 1/1/12 3/31/12 Date 6/29/12 9/27/12 18
kwe Analysis Tools 5000 4500 4000 3500 3000 2500 2000 kwe vs. T1, base load, Rice Univ. MONITORING DATA y = 21x + 5550 0 20 40 60 80 100 T1 ambient, deg. F kwe 6000 5500 5000 4500 4000 3500 3000 2500 2000 kwe vs. T1, base load, Ref. Unit 1 y = 31.275x + 5179 20 10 0 10 20 30 40 T1 amb, deg. C kwe kwe vs. T1 at base load, Ref. Unit 2 6000 5500 y = 31.275x + 5179 5000 4500 4000 3500 3000 2500 2000 20 10 0 10 20 30 40 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
lysis Tools DP ratio and kw ratio, Rice Univ. PCD Ratio kw Ratio 0.4 011 1/12/2012 5/11/2012 Date 9/8/2012 1/6/2013 MONITORING DATA 1.6 1.4 1.2 1 0.8 0.6 kw actual / kw expected PCD ratio 1.3 1.25 1.2 1.15 1.1 1.05 CDP Ratio and kw, all data, Rice 5000 4000 3000 2000 1 PCD Ratio 1000 0.95 kw 0.9 0 8/1/11 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 2 590 570 550 530 510 490 470 450 012 3/22/2012 5/11/2012 6/30/2012 8/19/2012 Date Deg. C PCD, actual to expected 1 CDP ratio and TTex, Ref. Unit 1 600 0.95 500 T7 400 0.9 300 0.85 200 0.8 100 1/1/12 4/10/12 Date 7/19/12 10/27/12 T5, T7 deg. C
lysis Tools SFC, Btu/kW HR, Rice MONITORING DATA 1000 2000 3000 4000 5000 Generator output, kw Btu/kW HR 13000 12500 12000 11500 11000 10500 10000 9500 SFC, Baseload, Rice y = 0.001116x 2 9.912x + 3239 9000 3200 3400 3600 3800 4000 Generator output, kw 4200 4400 SFC Baseload T1, Rice y = 17.678x + 9351.8 50 60 70 80 90 100 110 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
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
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.