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COMPROMISE: AN EFFECTIVE APPROACH FOR CONDITION-BASED MAINTENANCE MANAGEMENT OF GAS TURBINES

Wei Chen a; Cyrus B. Meher-Homji b; Farrokh Mistree a a Systems Realization Laboratory, The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, Georgia, USA b Boyce Engineering International, Inc.,, Houston, Texas, USA

To cite this Article Chen, Wei, Meher-Homji, Cyrus B. and Mistree, Farrokh(1994) 'COMPROMISE: AN EFFECTIVE

APPROACH FOR CONDITION-BASED MAINTENANCE MANAGEMENT OF GAS TURBINES', Engineering Optimization, 22: 3, 185 201 To link to this Article: DOI: 10.1080/03052159408941333 URL: http://dx.doi.org/10.1080/03052159408941333

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Eng. Opt., 1994. Vol. 22, pp. 185-201

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COMPROMISE: AN EFFECTIVE APPROACH FOR CONDITION-BASED MAINTENANCE MANAGEMENT OF GAS TURBINES

WE1 CHEN', CYRUS B. MEHER-HOMJ12 and FARROKH MISTREE' 'Systems Realization Laboratory, The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, Georgia 30332-0405, USA. 'Boyce Engineering International, Inc., Houston, Texas 77099, USA.
(Received October 14. 1992; in Jinol form September 28, 1993)

A decision-based approach t o condition-based maintenance management of rotating machinery is intro-

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duced and illustrated by formulating and solving a multiple objective maintenance management problem for a 15 MW industrial pas turbine. The comoromise Decision Suooon is used because .. Problem amroach .. it provides a convenient way of incorporating both information from condition monitoring and considerations of factors such as machine degradation. operating cost (fuel cost). production loss, maintenance cost, environmental protection, machine availability, etc. The focus in this paper is on explaining the approach rather than on the results per se.

KEY WORDS:

Condition monitoring, multiple objective maintenance management. gas turbine. compromise Decision Support Problem.

NOTATION

BTP
CAT
c c

Ci Cit Co CT CEF
di D E EGT EL i

bearing temperature hourly overall cost for one overhaul cycle cumulative cost of fuel hourly interest charge total interest charge initial fuel cost total cost during one overhaul cycle compressor efficiency deviation variables for the system goals deterioration rate electricity profit exhaust gas temperature electricity profit loss during shutdown annual interest rate
I85

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W. CHEN ET AL.

OMC PMC To T,

T '
VIB VIS

overhaul maintenance cost preventive maintenance cost time between overhauls overhaul shutdown duration time to pay off the maintenance cost by savings in fuel cost vibration level lubrication oil viscosity

hrs in/sec
SSU

1 FRAME O F REFERENCE
The problem of maintenance management. In recent years aero gas turbine technology has been introduced in the design of heavy-duty industrial turbines. As a result industrial gas turbines have become more sophisticated and demand rigorously controlled maintenance'. The problem of maintenance management is also complicated because:
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High fuel prices mandate that turbines operate at minimum degradation. Maintenance involves interdisciplinary work teams that must take into consideration factors such as machine degradation, operating cost (fuel cost), production loss, maintenance cost, environmental protection, machine availability, etc. Amongst these factors, there are at least three major tradeoffs: The tradeoff between maintenance cost and machine performance. The tradeoff between the costs associated with preventive maintenance and fuel costs associated with operating the turbine when it is a less than efficient (degraded). The tradeoff between overhaul costs and increased turbine availability as well as reduced production loss. Usually a fast overhaul, and hence a longer time for the turbine operation and less production profit loss, is accompanied by an increase in the cost of the overhaul. Mathematical modelling of maintenance management is essential to gain an understanding of the maintenance process. Ideally, maintenance considerations will be introduced during turbine design, as has been proposed in Concurrent Engineering"'. Condition monitoring has been proven to be essential for cost-efficient maintenance management in industrial, marine and aircraft applicationses. Using this technique can safely extend the interval between overhauls, minimize the number of openinspect-and-repair cycles, and improve maintenance efficiency by directing repair and overhaul actions toward specific deficiencies, etc. However, maintenance schedules based on condition monitoring alone cannot take into account the other important factors mentioned earlier or the tradeoffs between them. Because of the complexity involved, maintenance planning is currently based on personal experience and heuristic rules with the aid of condition monitoring. In order to meet

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187

the maintenance challenge an advanced maintenance strategy is required to achieve multi-level requirements.
Approach: A decision-based perspective for the solution of maintenance manage-

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ment problems is proposed in this work. Decision Support Problems (DSPs) are being developed and implemented to provide a means for modeling decisions encountered in design in a computer-assisted environment9. DSPs are categorized as selection, compromise, hierarchical and conditional DSPsl". The integration of condition monitoring and the compromise DSP for maintenance management proposed by Meher-Homji, et al.". The efficacy of using Decision Support Problems in maintenance management is reported in Chen". In this paper a method for using a compromise DSP to solve a condition-based maintenance management problem is demonstrated. Here the method is emphasized rather than specific results. Compromise DSPs refer to a class of constrained, multi-objective optimization problems which have a wide variety of engineering application^'^. The compromise DSP formulated in this paper addresses the decisions of when a gas turbine should be overhauled, how long the overhaul should last and how much preventive maintenance should be done during these overhauls. The model is based on a condition-based preventive maintenance policy which covers the following: Periodic maintenance is performed during overhauls to keep components in satisfactory operating condition. This is achieved by means of systematic inspection, detection and prevention of incipient failure. Condition monitoring is performed to discover the actual state of the system and decide the preventive and overhaul maintenance actions. The decision to overhaul the turbine is based on both information obtained by on-line monitoring and on a n a priori model of the deterioration process. The importance of the integration of compromise DSP with condition monitoring lies in the fact that the DSP must be based on the actual running condition of a specific gas turbine as well as on overall considerations such as costs. It is accomplished as follows: First, the performance degradation of the particular gas turbine is monitored by collecting information about such factors as gas path analysis (e.g., gas pressure and temperature), mechanical performance (e.g., vibration level) and the accessories (e.g., lubrication analysis, ultrasonic monitoring and visual inspection). Second, the data collected is validated, corrected and compressed to provide reliable and simplified information for subsequent analysis. Third, for data analysis, dominant health parameters are identified for the representation of turbine health and performance constraints/goals. The relationships between these parameters and the system variables are determined using empirical or theoretical relationships, statistical analysis or other mathematical approaches. Also ihe constraint limits (or goal target values) are specified for degradation limit checks.

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Finally, the health and performance constraints/goals are incorporated with other constraints/goals into a compromise DSP. Solutions to the compromise DSP in terms of the system variables provide the most favorable operational and maintenance requirements for the turbine. Focus: The approach is demonstrated by presenting the formulation, solution and validation of a compromise DSP for condition-based maintenance scheduling. A 15 MW industrial power generation gas turbine is taken as the study case. The formulation of the condition-based maintenance scheduling compromise DSP is presented in Section 2. In Section 3 the validity and stability of the solutions are confirmed. Conclusions, achievements and possible future work are presented in Section 4.

2 FORMULATION OF A COMPROMISE DSP FOR GAS TURBINE MAINTENANCE

2.1 Problem statement for maintenance scheduling
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In order to make decisions involving maintenance, it is desired to find the appropriate values for time between overhauls, overhaul shutdown duration, and deterioration rate. The gas turbine studied is a 15 MW industrial power generation turbine with 27% initial thermal efficiency. Its hourly fuel consumption is estimated as 4.6 x 10' m3. The initial fuel cost is $870/hr. It is known that-the loss in profit is about $1,00O/hr if the gas turbine is shut down for overhaul. The current interest rate is 15% per annum. Based on historical data, preventive maintenance cost (PMC) during gas turbine operation is formulated as the function of deterioration rate D, and overhaul maintenance cost (OMC) is formulated as a function of overhaul shutdown Time T,. In addition to the health condition of the gas turbine which is an essential consideration for maintenance scheduling, it is also necessary to minimize the overall cost (consisting of operation cost, preventive maintenance, overhaul maintenance cost, downtime production profit loss and interest loss). Ideally, the overall costs should be no more than $900/hr. A performance effectiveness (overall thermal efficiency) of 22% is expected. The pollution caused by NOx emission must be minimized below 40 ppm. 92% availability of the gas turbine is expected.

2.2 Descriptions of system variables, constraints, goals and deviation function for maintenance scheduling

System variables, constraints and goals are identified for the compromise DSP formulation on the basis of the problem statement given in Section 2.1. Description of the system variables: The system variables for the maintenance scheduling compromise DSP are, (1) time between overhauls (To), (2) overhaul

GAS TURBINE MAINTENANCE

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shutdown duration (T,) and (3) deterioration rate (D). Time between overhauls (To)is the time between two overhauls. The timeline for the whole overhaul cycle of the gas turbine is shown in Figure 1. Overhaul shutdown duration (TJ is the duration of overhaul maintenance actions or the time between stopping and restarting the turbine. Here the shutdown time is taken as a system variable that can be 'controlledn based on the change in electricity production loss and availability requirements. The overhaul duration can be shortened by assigning more labor or executing replacement to replace repair. The tradeoff must be made between the shortened duration and the increased overhaul cost.

Deterioration rare (D) is the degree of accumulated deterioration over a specific time. Engine deterioration is measured by an increase in specific fuel consumption. The performance deterioration may not be fully recoverable with preventive maintenance, e.g. loss of tip clearance, erosion effects and seal leakage, etc. In Figure 2, the influence of preventive maintenance on the deterioration rate is illustrated schematically. The thinner line represents the change of functional effectiveness of the turbine with a greater amount of preventive maintenance while the thicker line
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Start One overhaul cycle

Start

% 1 -J

Time Between Overhauls

str-L
1

Running time

Overhaul Shutdown Duration

Figure 1 Gas turbine overhaul

cycle.

Larger Preventive Maintenancevolume

Degradation limit ---------------Smaller Preventive Maintenance Volumel -Reduced Time Between Overhauls I
I

'

Operating Hours
Figure 2 Influence of preventive maintenance volume

on deterioration rate.

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W. CHEN ET AL.

represents a smaller amount of preventive maintenance. It is obvious that the deterioration rate (D) is reduced if more preventive maintenance, such as compressor washing, is undertaken and the time between overhauls is extended. Therefore the selection of D, the deterioration rate, can be used to determine the appropriate amount of preventive maintenance.
Description and derivation o f the system constraints: The machine health con-

straints are taken as system constraints to ensure that the degradation of a gas turbine is within certain limits before overhaul. Either measurable parameters or performance characteristics can be factored into the health constraint equations. It is recommended that the factors chosen should reflect the most frequently occurring problems with gas turbines. Here six health parameters have been selected to represent the dominant health constraints.
Vibration level constraint (VIB): Vibration measurement is a well-established

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technique for the condition monitoring of rotating equipmentl6I6. It can be used to identify the source of the vibration, e.g., unbalance misalignment, inappropriate blade passing frequencies or surging and combustion pulsation problems. The allowable maximum overall vibration level is 0.42 in/sec.
Exhaust gas temperature constraint (EGT): Measurement of the EGT is essential regardless of the type of analysis. High EGT indicates either an excessively high turbine inlet temperature or a faulty turbine; perhaps there is combustion of fuel nozzle plugging, compressor fouling or other problems. EGT must be limited at a selected baseload. EGT cannot exceed 1,020F. Compressor efficiency constraint (CEF): Compressor efficiency itself is not directly measured, but is computed from the overall pressure ratio (combustion shell pressure divided by the ambient pressure or preferably the inlet and discharge compressor temperature). The compressor efficiency reflects deterioration in the compressor section and is especially sensitive to compressor fouling1'. The lower limit of compressor efficiency is 84%. Lubrication oil viscosity constraint (VIS): Monitoring the viscosity of the lubrication oil is another important method of investigating turbine malfunctions by detecting oil c ~ n t a m i n a t i o n ' ~A - ~change ~. in viscosity is caused by a change in lube oil properties or by a change in the condition of the machine. Considering the long term trend of debris collection, the minimum acceptable viscosity is 100 ssu. Bearing temperature constraint (BTP): When a bearing is subjected to strong radial loads or excessive bearing loading due an increase in bearing shell temperature, there is an increase in bearing metal temperature. Bearing temperature provides corroboratory evidence on bearing condition and should be used in conjunction with vibration monitoring16. The maximum acceptable bearing temperature is 95C. Nozzle crack constraint: In some aero engines, a correlation has been found between deterioration and cracks1'. This constraint has been introduced to show conceptually how additional health constraints are added. The nozzle crack con-

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straint is formulated using discriminant analysis which is a technique for the description and testing of between-group differences". For this maintenance problem, sample published data has been collected and two groups (requiring overhaul - not requiring overhaul) have been identified. Among the above health constraints, except the vibration, exhaust gas temperature constraints are based on the on-line monitorine, - data and nozzle crack constraint is obtained by discriminant analysis, the other health constraints are formulated using historical data obtained from condition monitoring. Regression a n a l y s i ~ ~ ' - ~ is used to provide statistical information about the multidimensional parameters. The solutions are summarized in Section 2.3. Detailed analysis and formulations can be found in Chen".

Description and derivation of the system goals: The description and derivation of the overall hourly cost, efficiency, availability and emission control goals are: Goal I-Overall hourly cost goal: 0;erall cost within one overhaul cycle consists of three parts: the operating cost, the maintenance cost and the interest charge. Each component of the overall cost is described as follows: Operating cost: Deterioration in specific fuel consumption will greatly increase the operation cost of a turbine. As it is assumed that the engine is returned to the "as new" condition after every overhaul and the engine deteriorates linearly at a rate D, the calculated cost of fuel consumed during one overhaul cycle is

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Maintenance cost: This consists of overhaul maintenance cost (OMC), preventive maintenance cost (PMC) and downtime electricity profit loss (EL). EL is related to the loss of electricity profit during overhaul, it is assumed that EL is linearly related to the shutdown time (T,):

Interest charge: If the turbine is unused, interest payments on the cost of overhaul will accumulate without compensating saving in the cost of fuel. This is simulated by crediting the saving of fuel cost against the cost of overhaul and production loss until it is paid off, and charging simple interest against the outstanding balance. The derivation of the total interest cost C,, over one overhaul cycle is given in ChenI2, it is omitted here.

The Overall cost C, is calculated by adding. the different costs:

over one overhaul cycle To + T,, the total Considering the average hourly cost CAT cost is expressed for two cases and summarized as follows:

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W. CHEN ET AL.

Case A:

When

PMC

+ OMC + EL ITo + T,
CODTO

CAT=

Co( T o 0.5D T,)' To + T,

(PMC

+ OMC + EL)
To + T,

+ OMC + EL)2 + 2 i(PMC x 8766 CODTO( To + T,)

Case B: When

C A ~

c0 ( T+ ~ 0.5D
To + Ts

(PMC

+ OMC + EL)
To + Ts
(7)

+ EL) - C a T o ( T o+ T,) ] + i[2(PMC + OMC 2 x 8766

The overall cost goal is
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where CATis actual average overhaul cost, and d;, d : are under- and overachievement deviation variables. The compromise DSP formulation must be established for both cases A and B. Eqs. (4) and (6) provide system constraints in each case, solutions with smaller values of the deviation function will be chosen.

Goal 11-Overall turbine efficiency goal: The overall turbine efficiency q,, is a measure of output power compared with input energy. From the designer's viewpoint, it is important to meet power demands and limit fuel expenses. Regression analysis of simulated historical data gives a relationship between the overall turbine efficiency and the system variables
In this problem, an efficiency of at least 22% is specified. The overall turbine efficiency goal is therefore given by the following equation:

(5.084/(T0&) - 0.001)/22 + d;

- d:

= 1.0

(10)

Goal 111-NOx emission control goal: Given the current level of environmental concern, the limit on the emission level (EMS) is of great importance. In fact, in the near future, maintenance may be driven by NOx and efficiency consideration~~ Violation ~. of emission level limits results in penalty costs which would decrease profits. Regression analysis on simulated historical data shows that relationship between the emission level and the system variables can be expressed as EMS = 48000.85D 901.692 + 1 1 . O 7 To - 0.24 T:

+ 2.197

GAS TURBINE MAINTENANCE

193

It is expected that the gas turbine NOx emission level will be less than 42 ppm. The emission level goal is given by the following equation:

Goal IV-Availability goal: Gas turbine overall availability (AVB) is a measure of the amount of time the unit is actually available to produce power in any given period. In terms of the system variables, the theoretical overall availability becomes

As it is assumed that the shutdown time for preventive maintenance is neglected, the AVB value obtained from Eq. (13) must be larger than the actual value, an approximate correction factor of 0.94 is used. Then Eq. (13) becomes AVB = 0.94Downloaded At: 14:58 6 January 2010

T o

+T s

x 100%

It is expected that the availability must be at least 92%. The availability goal is given by the following equation:

The deviation function: The solution of a compromise DSP minimizes the deviation function which consists of undesirable deviations from the system goals. There are various methods of measuring the effectiveness of the minimization of these deviations. In the authors' opinion, the lexicographic minimum concept is the most suitable approachz6. As an example, consider two solutions, f ' and f', where f ' = (0, 10, 400, 56) and f ' = (0, 11, 12, 20). In this example, f ' is preferred to f". The value 10 in f ' is smaller that the value 11 in f'. Once a preference is established, then all higher order elements are assumed to be equivalent. Hence, the deviation function, Z, for the preemptive formulation is written as V,(d-, d + ) , . . ., f,(d-, d + ) ] . In the present model, the first priority level is assigned to minimizing the overall cost and emission level and maximizing the efficiency and availability. As the overall cost is always the most important factor, engine performance (efficiency) is the next most important, and emission control and availability are the least important, weights of 0.4, 0.3, 0.15, 0.15, respectively, are given for each goal. In priority level 11, the overall efficiency and emission level are expected to attain the target values. These are less important goals as compared with those in level 1. Therefore the deviation function is Minimize Z = [ (0.4d: (0.5d:

+ 0.3d; + 0.15 dl + 0.15 d;), + 0.5d;) I

(16)

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W. CHEN ET AL.

2.3 Mathematical formulation of the compromise DSP

Based on the description of the constraints and goals in Section 2.2, the mathematical formulation of the compromise DSP is as follows: Find Independent system variables To, T,, D Deviation variables d t , d ; Satisfy
System constraints

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Health constraints VIB: 0.069 - 0.007T0 + 0.001T; 5 0.42 EGT: 901.18 - 4.887, - 0.096T: 5 1020 CEF: 0.914 + 0.002T0 - 1.6 x 104T; - 0.0560 2 84 VIS: 149.76 2.512T0 - 0.1 Ti - 50.080 2 100 BTP: 66.13 0.138T; + 50DZ- 4.1 ToD 5 95 Nozzle crack: D + 0.05To 5 2

+ +

Constraints due to cost derivation Case A Case B PMC PMC

+ OMC + EL 5 To + T,
CODTO

+ OMC + EL,
CODTO

To

Ts

(either A or B is used for each possibility)

System goals

Overall cost: C,,/900

+ d ; - d:

= 1.0

(8)

Overall thermal efficiency: ( 5 . 0 8 4 / ( ~ , a ) -0.001)/22 Emission level:

+ d;

- d: = 1.0 (10)

48000.850 : 901 .692 11.07 To - 0.24 T

+ 2.1971 1 4 2

1 0 x 100%/0.92 Availability: 0.94 T o + T,

+ d;

- d: = 1.0

Bounds on the system variables

10 5 To 5 25 0.5 5 T, 5 1 0 5 0 s 1.3

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Minimize

The preceding DSP provides a specific mathematical model for maintenance scheduling. Deviation variables are associated with various goals. The objective then is to minimize the sum of these deviations. System and deviation variables (generally represented by d; and d;) in a compromise DSP are always nonnegative. To effect solution, one of the following three conditions must hold, namely; [(d; = 0) and ( d l = O)] or [(d; = 0) and ( d l > 0) or [(d; > 0) and (d: = O)]. This requirement is modeled by: [(d;. d l = O)]. Details are provided in Mistree et aL9

3 IMPLEMENTATION AND VALIDATION

3.1 Solution of the compromise D S P for maintenance scheduling The DSP was solved on a SUN 4/110 and 4/260 series computer using the DSIDES software9. Tests are run using different starting points for Cases A and B to check the convergence of the solutions. These are reported in Chen". Solution convergence indicates that the model is well formulated and the algorithm used is feasible. Numerical solutions for Cases A and B are presented in Table 1. Observations: The solutions for both cases provide meaningful results. As the deviation function of level I in Case B is smaller than that in Case A, the solution of Case B is selected to be the solution. Comparing the values of system variables and goals in both cases, we find the time between overhauls, To, for Case B (22.24 x 10' hrs) is slightly larger than that for Case A (21.97 x I d hrs). Deterioration rate, D, .for Case B (0.7024 %/4000hrs) is smaller than for Case A (0.9017 %/4000hrs). It is also noted that for Case B the goals are better satisfied than for Case A. This indicates that extending the time between overhauls by taking more
Table 1 Solution o f the compromise DSP in Case A and Case B.
Case A Cue B

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SYSTEM VARIABLES Time Between Overhaul To (ldhrs) Shutdown Time T, (ldhrs) Deterioration Rate D (Vd4.000hrs)
DEPENDENT VARIABLES Cost (target value 900 $/hr) Efficiency (target value 22%) Emission Level (target value 40ppm) Availability (target value 92%) Deviation Functions Priority level I Prioritv level I1

1%

W. CHEN ET AL,

preventive maintenance work is beneficial for minimizing - the deviation function (maximizing goal achievement). In both cases, Shutdown time, T,, attains its lower bound, i.e. 500 hrs. This means that, in this formulation, to achieve the availability goal and reduce profit loss the smaller the T, the better.

3.2 Parametric studies of the maintenance template

Parametric studies were performed to demonstrate that the solution is close to reality and to give confidence in the results. Parametric studies help verify that the model obeys the laws of physics, and that its behavior is intuitively correct. These studies are also useful for investigating the sensitivity of the maintenance decisions to changes in parameters. The effect of change in electricity profit, compressor efficiency constraint limit and goal target values are shown as examples here.
Effect of change in electricity profit: One reason why the overhaul shutdown time (T,) in both cases reaches the lower bound is because the goals of reducing the electricity profit loss and achieving availability are more important than the savings in overhaul cost by extending the overhaul cycle. Therefore, the change in electricity profit as well as the electricity profit loss may affect the solutions. The effects of electricity profit on the deviation function, overhaul shutdown time, overall cost and availability change over the range of $(500-1,40O)/hr of electricity profit are plotted in Figure 3 at five sample points. Observations: It is noted that the deviation function at level I of,Case A is quite close to that of Case B at lower electricity profit values. However, within the range

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400

800 1200 1600 Electricity Profit ($h)

920 910
400

800 1200 1600 Elecaicity Profit ($fir)

Figure 3 Effect

90

400

800 1200 1600 Electricity Profit 6hr)

of the

electricity profit.

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197

of study, the solutions to Case B are always preferred. This phenomenon indicates that extending the time between overhauls by taking more preventive maintenance isalways beneficial. While the time between overhauls and deterioration rate are quite stable, the change in electricity profit within the $(500-850)/hr range indicates its strong impact on the overhaul shutdown time, T,. As the overall cost goal and availability goal are strongly related t o the recommended T,, changing them causes the changes in the two goals. The graphical solutions match very well with our intuition and the mathematical analysis of the formulation. Effect of compressor efficiency constraint limit: The compressor efficiency constraint limit must be chosen by a maintenance engineer. In our example, 84% has been selected. It is necessary to examine the response of the DSP to either reduced or expanded constraint limits. Four tests are run for both Cases A and B within the range of 82% to 87% of compressor efficiency. As all of the deviation functions at priority level I of Case B are all smaller than those of Case A, solutions to Case B are preferred in all the tests. The solutions are provided in Table 2. The effects D and overall cost goal are illustrated in Figure 4. on the To,
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Observations: From Table 2, it is seen that the shutdown time is quite stable. However, time between overhauls and deterioration rate are all affected by changes in the compressor efficiency constraint limit. By increasing the compressor efficiency constraint limit, values of time between overhauls and deterioration rate all decrease while the overall cost increases. This is in keeping with reality. Increasing the compressor efficiency constraint limit is more conservative, hence more conservative decisions are required for time between overhauls and deterioration rate. The increase in overhaul cost also reflects the trade-off between the technical and economic factors. Effects of changes in goal target values: Target values could change with the condition of the company, outside regulations or other management considerations.
Table 2 Effect of compressor efficiency constraint limit.

LIMIT 0 84%
SYSTEM VARIABLES To (Idhrs) Shutdown Time Ts(Idhrs) Deterioration Rate D DEPENDENT VARIABLES Cost (S/hr) T = 900 Efficiency (%) T = 22 Emission Level @pm) 7 = 40 Availability (70)T = 92 DEVIATION FUNCTIONS Level I Level 11 22.2410 0.5000 0.7023

LIMIT I 82%
22.5500 0.5000 0.7547

LIMIT I I 85Y 'o

21.4023 0.5000 0.6034

LIMIT 1 1 1 87%
19.6656 0.5000 0.4642

918.77 24.50 34.95 91.93 0.0084 0.1199

918.77 23.30 37.39 91.96 0.0084 0.0623

919.70 27.48 30.35 91.85 0.0090 0.2451

924.30 34.12 23.90 91.33 0.0122 0.4767

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Observations: From the solutions provided in Table 3, it can be seen that, for the changes of the cost target value (Scenarios I and 11), values of system variables remain stable. This is due to the restricted design space formed by health constraints. Within that space no better solution can be achieved. The use of more restricted regulations for emission control has an impact on the solutions (Scenario 111); time between overhauls and deterioration rate are reduced as they were for the conservative design. The solutions of Scenario IV shows that there is no change in the values of system variables when greater availability is expected. This is also due to the restricted design space formed by health constraints. The parametric studies on target values show that, generally, the effects are quite limited. However, the solution will be affected if the change is not small, as is the case in Scenario 111. The effects of changing the fuel cost, coefficient of preventive maintenance cost, interest rate, unit incremental overhaul maintenance cost and the goal priority levels were also studied in this work. These are described in detail by Chen12.
4 CLOSURE
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This condition-based preventive maintenance approach shows great potential for use by gas turbine operators. Accuracy in degradation detection, data management and pattern recognition is enhanced by using a compromise DSP based on on-line condition monitoring, borescope inspection and the mathematics of discriminant analysis and regression analysis. The compromise DSP is an effective tool for modeling and solving multiobjective maintenance management problems. The validation of the maintenance template gives a deeper insight into the problem of gas turbine maintenance and makes it possible to predict the responses of the solutions to the changes of maintenance parameters. It is recognized that a great deal of work is still required to refine this model. Much more accurate information on the parameters representing health must be collected to establish accurate relationships between mechanical and aerothermal parameters. The use of on-line condition monitoring systems can facilitate this. The parametric study could also be improved by studying the combined effects of several parameters. In the longer term, understanding of maintenance processes and their effect on designing is necessary for furthering Concurrent Engineering Design.
Acknowledgments This work was completed while the first and third authors were at the University of Houston. We gratefully acknowledae the financial contribution made by our coroorate soonsor. The BE Goodrich Company, for the further development of the Decision ~ u b ~ o problem rt ~ e c h n i ~ uA e . grant from the Texas Advanced Technology Program (Grant No. 3652-227) and the NSF equipment Grant 880681 1 are both aratefullv acknowledaed. The cost o f comDuter time was underwritten bv The Svstems Desinn Laboratory o f The ~ n i v e r s c of ~ Houston.

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References

W. CHEN E T A L .

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