GAS TURBINE & RECIPROCATING ENGINE
MARKET UPDATE
February 1, 2017
McIlvaine Company
TABLE OF
CONTENTS
REMOTE
MONITORING AND MAINTENANCE
Siemens monitors more than 9,000 Turbines at its
European Data Center
GE Power and Tepco will jointly Develop Solutions for
Japanese Fleet using Predix
Parker has Condition Monitoring for Gas Turbines
GE Monitors 1500 Gas Turbines at its M&D Center
Ansaldo operates Remote Monitoring and Diagnostic
Center
IHI Remote Monitoring System for more than 77 Gas
Turbines
Turbine Services supports Sites with Different Make
Turbines
EUROWATER supplied Water Treatment for 640 MW Polish
CCGT System
Pasadena has Contract with Puretec for Gas Turbine
Water Conditioning Services
Yara NOx Control Inventory Management and
Telemetry Services to Optimize Reagent Usage
GE provides Remote Gas Turbine Monitoring and Support
All technologies for Siemens Digital Services are pooled
under the new Sinalytics platform, explained Thilo Libuda, head of marketing for
instrumentation, controls, and electrical within the Siemens Power & Gas
Division: “It combines proven capabilities for remote maintenance and
optimization with the latest developments in data analysis, connectivity, and
cybersecurity.” It can also integrate engineering data or data generated by
people, Libuda said.in an interview with
Power Magazine.
Sinalytics works both in the cloud and locally—for example,
at a Siemens data center in Europe or the U.S.—or by intelligent networked
devices in the field, where data are generated.
Siemens monitors more than 9,000 turbines (wind and
fossil-fueled) online. Every day, the gas turbines generate some 26 GB of data
while wind turbines generate 200 GB. Remotely monitoring turbines can provide
multiple benefits, including longer service intervals and predictive maintenance
and maintenance planning, which can lead to increased profitability for
customers. For wind turbines, Siemens says it can provide remote remedies for
85% of all alarm situations.
Libuda emphasized the company’s comprehensive cybersecurity
program that allows confidential data to be transmitted and analyzed securely
plus technologies to “detect and investigate attacks from the Internet and
defend against cyber-attacks on critical infrastructure components.”
GE Power and Tepco Fuel & Power Inc. have signed a
memorandum of understanding (MOU) to jointly develop and introduce industrial
solutions throughout the utility’s thermal power plant fleet, harnessing GE’s
secure, cloud-based Predix platform.
As the first step in this agreement, Tepco FP will install
GE’s Asset Performance Management (APM) software in the LNG-fueled Futtsu Power
Station Unit 4 in Japan.
“As we look at the future energy needs of our customers, we
must invest in the latest digital solutions that can help us increase the
productivity, efficiency and reliability of our existing power plants,” said
Toshihiro Sano, president of Tepco Fuel & Power Inc. “We look forward to
developing a new business strategy with GE by harnessing Industrial “Internet of
Things (IIoT) technologies that will create new customer value at our domestic
and overseas thermal power plants and deliver improved reliability for our
customers through improved plant economics.”
APM and other Predix-based applications connect industrial
assets, collecting and analyzing data to deliver real-time insights to help
improve plant performance and operations for both GE and non-GE assets, the
companies said.
The Futtsu APM installation marks the launch of a digital
transformation of the utility’s existing fleet of thermal power plants to
increase their long-term reliability, flexibility and to help reduce life cycle
costs for Tepco FP. Tepco FP and GE are pursuing the digital APM software
solution at Tepco’s 1520 MW Futtsu site to improve the operator’s equipment
condition monitoring and diagnostics capabilities to increase plant reliability
and also to use big data and analytics to promote Tepco FP’s business and
operational optimization, the companies said.
“Futtsu Power Station, Tepco’s third largest natural
gas-fueled power plant and one of Japan’s most efficient power stations, is
located in Chiba prefecture, 30 km east of Tokyo. GE is scheduled to begin
installing the APM solution at the station in 2017.
Condition monitoring plays a significant role with that. By
employing an effective solution that monitors the temperature, pressure, and
humidity levels of a plant’s assets, operators can diagnose problems or damage
to turbines and inconsistencies among processes. Addressing and repairing these
issues before they become problems saves downtime and replacement costs.
Humidity and moisture in the gearbox can cause less than
optimal operation of rotary components, leading to corrosion, reduced product
quality, and ultimately breakdown. Monitoring a system’s performance can be a
good indicator of any potential problems with a turbine. By keeping tabs on a
system’s humidity, as well as the ambient humidity of the plant, operators can
gauge any potential effects to a turbine’s performance.
To keep a turbine operating consistently and with minimal
chance of overheating, it is necessary to keep components within the gearbox
well lubricated and cooled with clean oil. A good filtration package is also
important. Monitoring changes of a system’s temperature and pressure levels can
help operators identify when filters and/or oil in the turbine may need
replaced.
Also, monitoring for increased fuel consumption and/or
reduced output could indicate a more serious problem, such as compromised
integrity of rotary components within the turbine. Such issues can lead to
displacement or damage to toothed gears, blade damage or fatigue failures and
other structural damage that will ultimately impact a system’s performance.
Parker’s SensoNODE™ Blue sensors and SCOUT™
Mobile software allow users to monitor conditions using multiple sensors
simultaneously, each measuring the temperature, pressure, or humidity of
specific points within a system. Using Bluetooth technology, the sensors
transmit large volumes of data to mobile devices wirelessly, keeping operators
out of dangerous situations.
Every day, at its Monitoring & Diagnostics (M&D) Center, GE
collects more than 30,000 operating hours of data from a fleet of more than
1,500 gas turbine and generator assets, supplementing a 40-terabyte database
representing more than 100 million fleet operating hours. GE announced today
that the data-driven insights drawn from this volume of power generation “big
data” have translated to customer savings estimated at $70 million in 2014, up
from $53.9 million in 2013.
The Atlanta-based facility features a team of more than 50
engineers that analyze more than 35,000 operational alarms per year. Among the
activities monitored at the center are the inlet temperature of a compressor,
thermal performance of a gas turbine, temperature of combustion exhaust, dynamic
tones of the combustion system, vibration levels of a rotor and the temperature
of bearings. On a GE gas turbine unit there are more than 100 physical
sensors/300 virtual sensors.
“Our monitoring and diagnostics team and capabilities, play
a key role in helping GE customers operate their power plants at high levels of
performance and reliability,” said Justin Eggart, general manager, fleet
management for GE’s Power Generation Services business. “Our team takes a
holistic approach to what we call ‘predictive maintenance,’ which focuses on
helping customers sidestep operational barriers before they occur, no matter
what type of equipment they are managing.”
The ability to foresee and forestall issues is at the very
heart of predictive maintenance. Predictivity solutions for GE’s power
generation customers harness massive volumes of data analyzed from one of the
world’s largest monitored gas turbine fleet to develop solutions that allow them
to make more informed operational and business decisions.
Drawing on the experience of hundreds of thousands of
resolved cases, GE’s M&D team has developed dozens of physics-based, proprietary
algorithms that provide early warning of more than 150 potential failure
mechanisms. This wealth of physical understanding, blended with application of
statistical methods, has enabled the team to continually improve the algorithms,
thereby increasing the probability of detection while reducing false alarms.
In addition to GE units, this remote monitoring can be
applied across a customer’s entire fleet. Through device-agnostic predictive
solutions, the M&D Center monitors technology and equipment not only from GE,
but also Nooter/Eriksen, Flowserve, Emerson, Delaval, Byron Jackson and others.
GE also has made substantial improvements in reducing trip
rates since the M&D Center opened in 1996. For example, trips per thousand hours
for the combined 7F and 9F monitored fleet of gas turbines are down
approximately 25 percent since 2009.
Additional regional support with these services is provided
to GE customers around the globe from other M&D locations in Scotland, France,
India and its newest centers in Dubai, Saudi and China. Using a broad range of
analytic tools, these teams diagnose problems ranging from possible failed
sensors to gas turbine compressor damage.
ADA™ Advanced Diagnostic Analysis is the Ansaldo
Energia suite for condition-based maintenance.
Based on its modular design, ADA™ allows for advanced
monitoring of main equipment parameters like steam and gas turbine performances,
gas turbine combustion, machinery vibrations, generator diagnostic, electrical
transients and others. Computing modules, automatic report generation, alarms
notification, large data storage capabilities are some of the key features of
this state of the art product in the field of remote monitoring and diagnostic.
Through Remote Monitoring, all the relevant data are
readily available to experts who, in many cases, can understand quickly the
situation and give helpful indications to solve the matter. If additional
on-site support is needed, Ansaldo can provide at short notice skilled engineers
who can assist directly and act as a link with the Operation Support Team.
Main advantages of Remote Diagnostic and Operation Support
are:
Remo-moni™ is IHI's Remote Monitoring System
(RMS) of Gas Turbine Driven Generator Power Plants. Remo-moni™ is an
advanced monitoring system for gas turbine power plants. IHI has the ability to
observe the customer's plant from the IHI monitoring center and advise on
operations and maintenance, Benefits include:
a) safe operations,
b) improving high availability and
c) saving maintenance costs of gas turbines power plant
operation.
Remo-moni™ is installed easily by connecting to
the internet. Since 1995 the number of installations has grown to 77 units and
47 sites. In the event of an emergency, an IHI engineer will utilize the Remo-moni™
to find a solution for the customer. IHI Service Engineers can also be
dispatched.
The site is connected to the center through a computer,
route and ASDL modem furnished by IHI.
Monitoring and diagnostic systems supplied by independent
service providers rather than turbine manufacturers can be deployed to suit the
operators' requirements, rather than what might suit the manufacturer. And they
can be used with different turbine makes and models, and for other types of
plants. This is the argument made by Jonathan Aylett, of Turbine Services, a
Chromalloy company.
For example, a power utility has a fleet of peaking
turbines from different manufacturers and of different types, such as heavy
industrial and aeroderivative. The utility company uses the same system via the
internet to monitor all turbines remotely, and the system can send diagnostic
messages to cell phones and email reports to company staff. It has a flexible
client-server architecture which can be used in a centralized monitoring center,
or decentralized to any location able to connect a client remotely to a server.
It can also support remote clients running in web browsers.
Site data server acquires and archives data from the
turbine controllers.
Any number of remote clients can connect to it using the
company internal network, or remotely via internet or modem connection.
Data update rates for the remote clients can be configured
for the bandwidth of the network connection. This can be at once per second over
fast LAN or internet connections, or once per hour for slow modem connections.
For slow connections, remote clients can be configured to only download trend
data and diagnostic messages each day, reducing data transfers.
A typical data set of 400 analogue and 1500 digital tags is
acquired each second and analyzed 24/7. It is impractical to analyze this
manually, so the system analyzes the data in real time using diagnostic rules
and pre-alarm checkers, generating diagnostic messages which are archived on
site.
Standard sets of diagnostics have been developed through
the analysis of turbine data for many turbines over many years. They range from
simple pre-alarm analogue checkers to complex diagnostic rules using Boolean
logic combined with time based functions. Diagnostics are defined in parameter
files and addition and adjustment of these parameter files is all that is
required to adjust or add new diagnostics.
Diagnostic warning messages are generated at three fault
severity levels and are generated if the turbine starts to migrate out of a
tuned footprint, or if a fault occurs. Diagnostics parameters are tuned to each
turbine footprint and the parameters are periodically reviewed and retuned as a
turbine changes over time.
Digital controller data is acquired which enables the
system to report controller alarms, and enables diagnostics in the context of
the turbine run state (start up, base load etc.) and the detailed controller
operation of the turbine.
For long-term trending, the system creates trend files of
all data for each day. These trend files contain minimum, maximum and average
values of the data within five minute time windows. These trend files can also
be used to efficiently create trends for days, months or years.
The average trends show long-term changes such as a slow
increase in vibration, whereas the minimum and maximum values can reveal changes
that occur within the trend data sample window that would otherwise be lost by
averaging, such as vibration spikes.
The system can also check the turbine using event graphs
for start-ups, shutdowns and trips. This enables data for different time periods
to be plotted and compared on the same multi-time event graph.
To analyze turbine incidents such as trips, data can be
replayed. Historical data can be replayed by the system and viewed and analyzed,
just as it occurred at the time of the actual events. This is possible as data
is stored in a compressed format with no loss of resolution in time or value, so
any past data can be replayed at the original resolution of one sample per
second.
Remote monitoring and diagnostic systems can support an
effective preventive maintenance program, enabling proactive identification of
turbine problems that can be fixed in a timely manner. Turbine performance can
also be monitored and maintained. Without such systems, maintenance may be
reactive, and problems are more likely to occur with potentially serious
consequences.
EUROWATER has supplied water treatment plant for one of
Poland's largest Combined Cycle Gas Turbines with a generation capacity of 400
MVe and 240 MWt, located in the town of Stalowa Wola.
This project is one of the first state-of-the art large
CCGT gas fired power projects in Poland and part of Poland's drive to reduce
reliance on use of coal for power generation.
The water treatment plant is designed and built to supply
make-up water for high-pressure boilers as well as feed water for the district
heating network.
The water source is a river. First step of treatment is
coagulation and flocculation followed by sand filtration. EDR unit (electrodialysis
reversal) as partial desalination plant is used afterwards.
Hereafter the water undergoes membrane filtration on double
pass RO unit. Pretreatment to DPRO is antiscalant dosing and NaOH is dosed
between the RO stages to bind free CO2. Finally, the water is
polished on EDI in order to reach ultra-pure water.
Additionally fully automatic CIP system is available to
make easy cleaning of RO membranes when needed. The plant can operate with
flexible output due to VFD controlled RO pumps.
Technical data:
•
Silica: < 3 ppb (limit 20 ppb)
•
TOC: < 10 ppb (limit 100 ppb)
•
Flow: 3 x 25 m³/h
Units in plant:
•
Antiscalant dosing
•
Double Pass Reverse Osmosis, 3 x DPRO C4-28/20
•
Electrodeionization unit, 3 x EDI 4 x 5000e
•
Automatic CIP unit
This 2015 contract is for providing regularly scheduled
documented service, inspection, monitoring, and maintenance for the Water
Conditioning System for Glenarm and Broadway Power Plants. The Water
Conditioning System is a system that processes city water to high purity water.
The purified water is used for boiler make-up water for steam units; and cooling
system make-up water, air pollution reduction and efficiency enhancement for the
gas turbine units. This contract will ensure the efficient and reliable
operation Puretec met all the requirements of the RFP, received the higher
evaluated score, and is therefore recommended for award of the proposed
contract. Puretec has been successfully providing water conditioning system
services for Broadway and Glenarm Plants under a contract which expired on June
4, 2015.
This time Puretec submitted a price that was $21,000 lower
than Evoqua Water Technologies. The requested amount of $138,000 includes the
consultant bid of $125,638.04 for a three year contract, plus approximately 1
0°/o contingency for unforeseen services and parts replacements, as well as for
the increased conditioned water demand during Unit GT5 commissioning in CY 2016.
PWP has an option to extend the contract for one additional two-year extension.
With Real Tech’s new Smart Sense Remote Monitoring
platform, Puretec clients can access real-time water quality data in minutes
from anywhere in the world at any time. Using a secure login in on the Real Tech
website, a single sensor or multiple sensor nodes can be monitored using a
computer or smart phone. Features
include:
The Yara telemetry solution can help manage, and in some
cases, optimize SNCR and SCR reagent logistics. The telemetry solution is a
web-based remote monitoring system which:
•
increases security of supply of NOx reduction reagent
•
simplifies reagent ordering and stock management
•
increases data management control
•
increases security of supply
The telemetry system handles reagent stock levels,
triggering a delivery when a predefined level is met. All telemetry orders are
automatically delivered, securing supply to where it is needed. This flexibility
allows for operator resources to fully focus on other business needs. However,
the operator can still be involved.
Yara can provide installation of everything from tank level
monitoring, to data collection and transfer, to a user friendly web-based
monitoring system, which can be accessed from the owners process computers,
office computers or smart-phones and tablets. The system is flexible, and can
also be used to collect and monitor other measurement data, such as temperature,
pressure or chemical sensors.
Developed to assist Customers in maximizing machinery asset
value and based on connectivity systems, the iCenter solutions are configured to
gather data from the site and transfer it to the Florence Headquarters Team.
The various services are designed to evaluate, maintain and
estimate operational data using different analysis models, adding value through
the direct link with the Oil & Gas technical team.
In iCenter are services developed to use proprietary
software to provide:
•
remote assessment of machinery conditions and
troubleshooting help
•
performance evaluation and comparison
•
tuning of combustion systems
•
gas turbine emissions prediction
GE Remote Monitoring & Diagnostics is a service based on
data acquisition and connectivity systems to gather data from plants. It is
focused on:
•
Highlighting potential or incipient failures
using customized diagnostic rules
•
Tracking machine performance during plant
operation
•
Sustaining overall efficiencies and maximizing
machinery productivity
•
Assisting in machinery troubleshooting; linking
the plant machinery with the original equipment manufacturer.
Remote Dry Low NOx Tuning - Remote tuning
technology enables rapid response to tuning needs, significantly improving the
reliability and availability of gas turbine applications.
Real-time diagnostics and tuning services are provided
through GE's Remote Services Center by certified GE engineers -eliminating the
need for time spent on traveling to the site. Remote tuning meets Customers'
business needs, offering the flexibility to schedule tuning during planned or
unplanned outages, and to tune during operation to optimize performance and
emissions. Structured as a Technology Sharing Agreement, the service also allows
the Customer to invest in the technology and benefit from its enhanced value
over time.
OPFLEXIs a service based on the use of data acquisition
systems and connectivity to gather data from plants focusing on:
•
maximizing efficiency over the operating range by
tuning control curves based on the actual operating point
•
quantifying the stress of hot gas path components
in order to manage maintenance and performance trade-offs.
Predictive Emissions Monitoring System (PEMS) - Worldwide,
government restrictions on gas turbine emissions are becoming increasingly
stringent. Gas turbine users are required not only to minimize emissions, but
also to evaluate them continuously. PEMS helps Customers as an effective
alternative to Continuous Emissions Monitoring Systems
McIlvaine Company
Northfield, IL 60093-2743
Tel:
847-784-0012; Fax:
847-784-0061
E-mail:
editor@mcilvainecompany.com
Web site:
www.mcilvainecompany.com