Performance

GAS TURBINE

Monitoring

Aerothermal performance monitoring provides tools to optimise operation

of gas turbines. Based on thermodynamic models, machinery component
conditions are continuously supervised and compared to baseline
conditions. Optimising inlet filter exchange, compressor on and off-line
wash intervals, contributes to large cost savings and increased production.
PERFORMANCE MONITORING
- provides all necessary parameters for assessment of the real performance
Component function deteriorates
during normal operation of a gas
turbine. Over an operational year,
there is a substantial reduction in
performance and efficiency
resulting in power loss and
increased fuel consumption.
However, most of this loss is
reversible by inlet filter exchange
and compressor on-line or off-line
wash. The optimum timing for
filter exchange or compressor
washing differs extremely
Classification
OPENpredictor provides functions to
TM
classify data into different machine
states. The performance monitoring
(or Functional Condition Monitoring,
FCM) uses the function to classify
data into different load levels.
The system uses recorded
measurements of the gas turbine.
This can be from the commissioning
of the gas turbine or from any other
arbitrary time. One set of
measurements is needed for each
load class. These measurements are
valid for the actual machine and they
form the baseline, the reference
performance, against which future
performance will be compared.
Example of
OPENpredictor mimic
TM
for a heavy industrial
gas turbine
between geographical locations
and through seasonal variations.
Other faults, such as increased tip
clearance, internal leakage and
corrosion are permanent and
develope typically at a much
slower rate. Without an
automated monitoring system, it
is very difficult to judge the actual
efficiency of a gas turbine,
because the performance and
heat rate depend on a set of
operating conditions, for example:
Integrated Aerothermal and
Mechanical Condition
Monitoring
TM
The OPENpredictor system
performs both FCM and Mechanical
Condition Monitoring, MCM. The
system provides a complete
condition assessment of the gas
turbine, gearbox and drive unit, to
minimise operation risk, optimise
inspection and maintenance
intervals, schedule filter exchange
and optimise the compressor wash
intervals.
Operation risks are reduced, as all
failure mode specific monitoring
tasks are performed automatically.
• Ambient temperature,
pressure and humidity
• Power output
• Fuel type
• Filter/Inlet pressure loss
• Turbine exhaust pressure loss
• Speed (Multi-shaft gas
turbine)
Variation in these conditions may
have an influence of more than
20% on the apparent
performance and efficiency.
Rotating equipment and Process
Engineers no longer need to
manually analyse massive amounts
of data sets, which typically contain
mostly redundant data. When the
TM
OPENpredictor system identifies
deterioration in mechanical or
aerothermal condition, the
specialists are warned via the
dedicated alarm systems.
Each individual 'alert' or 'alarm' can
be assigned to a dedicated user such
as Operator, Process Engineer or
Rotating Equipment Engineer. This
provides maximum efficiency for the
organisation related to individual
responsibilities.
Compressor Fouling
The compressor efficiency and
airflow reduction is forecasted. The
system will issue a forecast 'alert'
showing that these two parameters
will deteriorate to such values that a
compressor wash will be required
within a user specified time frame.
The integrated function of MCM and
FCM provides information that a
wash was effective, without resulting
in excessive unbalance or pressure
pulsations in the compressor
sections, which would lead to
increased fatigue.
 Therefore, to get an immediate
indication of deviation from base
line performance (the
performance when the machine
was new and commissioned) it
requires a thermodynamic model
of the process and a set of
thermodynamic measurements to
provide parameters for
assessment of the real
performance.
Combustor Pulsation
Combustor pulsations lead to
excessive dynamic loading of the
combustor liners and power turbine
blades and result in efficiency loss.
Early identification of combustor
pulsations can be used to change
fuel flow and load conditions to
avoid these problems. This function
is provided in the MCM application
packages, as pulsation frequency
analysis is used in the combustor
assessment.
Exhaust Gas Temperature plot
Filter Fouling
Filter fouling results in efficiency and
power loss. The user can specify the
maximum deterioration acceptable.
As the system corrects the actual
measured data to reference
conditions, a forecast can be
calculated. The system will issue a
forecast 'alert' showing the filter
fouling will deteriorate to a value,
which requires filter exchange within
a user specified time frame. This
allows planning of filter exchange at
the most economical moment.
Turbine Fouling
Reduced power turbine efficiency
leads to increased fuel consumption,
power reduction and increased CO2
production. Specifically at crude oil
fired systems, power turbine fouling
will develop. The forecasted
efficiency reduction can be used to
schedule inspection and cleaning.
Exhaust Temperature
Distribution
Large variation in the exhaust gas
temperature distribution to the
average value indicates combustion
problems leading to increased
thermal stress in the power turbine,
which has to be identified as soon as
possible. The classification of data
provides information on how to
change operation conditions to
minimise the deviation, avoiding
shutdown of the turbine.
Other gas turbine specific faults can
be monitored, forecasted and
diagnosed automatically, after
specification of the fault patterns.
Additional Manual Analysis tools are
provided in the application package
such as Multiple Trend Plots and 2
dimensional Scatter Plots with
extensive filter options to display
data only for specific operation
conditions.
AND IT WORKS...

The OPENpredictor system installed at Helsinki Energy’s Vuosaari B

TM

Power Plant provides on-line mechanical health information of all critical

machines.

The system also executes Performance Monitoring for the gas and steam
turbines.

Helsinki Energy’s overall objective was to combine machine mechanical

health and performance assessment as the basis for O & M decisions.
The standard delivered vibration protection systems could not provide
diagnostic information on machinery faults. The OPENpredictor system
TM

was purchased to further process the signals from the vibration protection
system sensors in order to identify fault symptoms hidden in the raw
signals. The control system did not provide information on the gas and
steam turbine performance. By transferring process data from the central
system to OPENpredictor , it is possible to calculate the machine
TM

performance and to analyse deviations from normal behaviour.

A gas turbine at Helsinki Energy’s
Vuosaari B Power Plant, Finland

Further information:
Please contact us for specific information on hard and/or software modules,
available as Product Data Sheets. Reference Installation Sheets are also
available.

ROVSING Dynamics is globally represented by its subsidiaries and sales

executives and exclusive contracts with distributors. All industries, no matter
where they are located, can benefit from the use of OPENpredictor . TM

ROVSING Dynamics Headquarters are situated in Copenhagen, Denmark.

CBR_0101_01

Copyright2001. All rights, title and interest in and the Software, Hardware and Services detailed in this document and all copyrights, patents, trademarks, service marks or
other intellectual property or proprietary rights relating thereto belong exclusively to ROVSINGDynamics A/S

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e-mail: info@rovsing-dynamics.com · www.rovsing-dynamics.com