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Netherlands Russia United Kingdom United Arab Emirates
Systematic and Sustainable Reduction
of Human Error in
Gas Turbine Operation & Maintenance
Guest lecture: RWTH - Institute for Jet Propulsion and Turbo Machinery
Location : Aachen
Date & time : Wednesday February 3rd 2016, 14:00 hrs.
Speakers : Fred Weenink – Education & Training Manager
Sjirk van der Goot – Business Development Director
Content
1. Introduction VBR Turbine Partners
2. The most important factor in operating and maintaining gas turbines
3. Decision making competence levels for gas turbine operation & maintenance
4. Systematic improvement of gas turbine operation & maintenance
5. Decision making in gas turbine operation & maintenance
6. Systematic improvement of decision making 1: education & training
7. Systematic improvement of decision making 2: decision support
8. Example of an operation & maintenance decision support system: RAPID
9. Summary
10.Questions?
Introduction of VBR Turbine Partners
Gas turbine
maintenance improvement
GE LM1600 LM2500 LM6000
Netherlands Russia United Kingdom United Arab Emirates
VBR solutions & services overview
Controls & Instrumentation
Mechanical Field Service
Condition Monitoring
Overhaul Consultancy
Education & Training
Spare Parts
Meggitt, WhittakerControlsValves
Meggitt, Whittaker ControlsValve overhaul
Esterline / Weston Aerospace
GasTOPS MetalSCAN
Cheng Cycle / Cheng Low NOx
JADwash
Troubleshooting, problem solving
RAPID remote operation support
Human error reduction
Maintenance agreements
Inspection, repair & replacement
Engine overhaul, hot section
Control system retrofit & re-commissioning
Remote DLE mapping
Strategic spare parts planning
Service interval & engine life extension
Power plant relocation
Emission reduction retrofits
Maintenance improvement solutions Maintenance improvement services
Authorized distribution
Over 230 corporate & public sector
customers
Maintenance service locations
Netherlands
Russia
United Kingdom
United Arab Emirates (Abu Dhabi & Dubai)
Maintenance service agents
Australia
New Zealand
Providing GE LM solutions & services
Europe
Russia
Middle East
Africa
Providing GE LM spare parts
all over the world
Contact details The Netherlands
VBR Turbine Partners headquarters & warehouseIndustrieweg Oost 66662 NE ElstThe Netherlands
+31 88 010 [email protected]
www.vbr-turbinepartners.com
Contact details United Arab Emirates
VBR Turbine Partners Middle East service officePO Box 17573Jebel Ali, Dubai United Arab Emirates
+971 4880 [email protected]
The most important factor in operating
and maintaining gas turbines
What is the most important factor in operating and maintaining gas turbines?
The most important factor in operating
and maintaining gas turbines
The human factor …
Research shows that 42% of the preventable lost production in the global
process industry is primarily caused by human error. (source: ARC advisory group)
Every day decisions are made by gas turbine owners, managers, procurement
officers, operators and maintenance engineers that affect the performance and
reliability of gas turbine units.
These decision makers have various levels of competence with regard to gas
turbines and they often underestimate the impact of their decisions on the
overall operation, maintenance and potential profitability of their turbine.
Decision making competence levels for
gas turbine operation and maintenance
Decision making competence levels for gas turbine operation & maintenance:
1. Unconsciously incompetent
2. Consciously incompetent
3. Consciously competent
4. Unconsciously competent
Ideally every owner, manager, procurement officer, operator and maintenance
engineer should at least be consciously competent about the impact of their
decisions on the overall gas turbine operation & performance.
Systematic improvement of gas turbine
operation & maintenance
The gas turbine operation & maintenance hierarchy of objectives and measures:
Revenue improvement depends on engine reliability, availability, performance & maintainability.
Cost reduction depends on predicting the most effective maintenance interventions &
minimizing fuel consumption, exhaust emissions and steam/water consumption.
Intuitive HMI
and good
controls
Improve
operational
reliability
MTBF:
C&I, FMEA
and FTA
MTTR:
Predict, plan
and track
Develop
plant
reliability
Model based
setpoints and
automation
Boost
production
Maximise revenue
Monitor
and
optimise
Operate at
best
efficiency
CMMS,
procedures
and spares
Decrease
maintenance
costs
Automation
and seamless
integration
Reduce
labour
costs
Minimise operating costs
Increase profits
Decision making in gas turbine
operation & maintenance
Each and every day plant managers, procurement officers, gas turbine operators &
maintenance engineers have to make many decisions on how to run their plant in the
best possible way.
The potential profitability of a gas turbine operation depends largely on the quality of the
day-to-day decision making by all these people involved.
Systematic improvement of these day-to-day decision making processes will result in a
sustainable improvement of the total plant operation & maintenance and therefore
in a sustainable improvement of the total plant profitability.
But how to realize this systematic improvement in day-to-day decision making?
Systematic improvement of decision making:
1. education & training
The common way reduce human error is to provide an education & training curriculum
and a career development path for plant managers, procurement officers, gas turbine
operators and maintenance engineers.
Over time they will become more knowledgeable, more capable and more experienced
which will improve the quality of their day-to-day decision making.
With the retirement of many very experienced plant managers, operators and maintenance
engineers it became very clear that the education & training approach (transfer of
knowledge and experience) by itself was not sufficient to ensure good and consistent
decision making for gas turbine operation & maintenance over a longer period of time.
Due to the lack of knowledge & experience of the younger managers, operators and
maintenance engineers the overall quality of the decision making tended to go down.
Systematic improvement of decision making:
2. decision support
A new way to reduce the human error factor is to support the decision making process of
(more and less experienced) managers, operators & maintenance engineers by a predictive
decision support system based on the actual behaviour of the gas turbine in operation.
Most traditional (remote) monitoring and diagnostic solutions focus on providing engine data
& statistics to gas turbine operators & maintenance engineers from the perspective that they
will immediately know the correct things to do at the very moment they receive these data.
Predictive decision support systems analyse all engine data & condition monitoring statistics
(online, real-time) and enrich these data with operation & maintenance knowledge &
experience to deliver practical day-to-day operation decision support for gas turbine
operators and maintenance action planning for gas turbine maintenance engineers.
Systematic improvement of decision making:
2. decision support
Key elements of a predictive decision support system for gas turbine operators & engineers:
• A simulator is configured to provide the ideal running data of the engine at its location
• All actual running data of the engine are collected (real time)
• The actual running data are compared with the ideal running data (real time)
• When deviations exceed pre-defined limits experienced engineers receive a message
• They analyse the running data to identify the most likely causes of the deviations
• They advise the operators and & maintenance engineers of the gas turbine what
will be the best (corrective & preventive) decision & maintenance action options
Example of an operation and maintenance
decision support system: RAPID
Reliability
Availability
Performance
Intelligent
Diagnostics
Experience shows that approx. 80% of all field
problems where external assistance is required
start as controls alarms.
Almost all fault alarms can be related
malfunctioning modules such as vibration
probes, temperature sensors, pressure
sensors, switches, cables and so on.
Before sending out a service engineer for
further root cause analysis, the RAPID remote
operation and maintenance support system
will already provide the critical information for
preliminary fault analysis.
Benefits of the RAPID remote operation &
maintenance decision support system
Benefits Customer
• Improved reliability
• Improved availability
• Improved performance
• Improved maintainability
• Enables effective troubleshooting
• Enables pro-active preventive &
predictive maintenance
• Reduces operation & maintenance
costs and total cost of ownership
Benefits VBR Turbine Partners
• High added value for customers
• Enables quick & effective
customer service & support
• Increases company expertise &
capabilities
• Enables effective maintenance &
efficient maintenance planning
• Provides new career development
opportunities for experienced
VBR service engineers
How does RAPID work?
Connect & collect: all relevant engine operation data
Analysis: use intelligent diagnostics to transform the collected engine data
into useful information and intelligent alarm management to gain insight
Interpretation: use the VBR expertise & experience to draw conclusions
from the information & insights gained
Feedback: VBR provides operation & maintenance decision support to
customers by transforming the conclusions into practical operation &
maintenance recommendations and into periodic engine health condition
reports
Connect & collect: engine operation data
InternetSecure VPN IPSectunnel
Customer Controls panel
CustomerHMI
VBR Data Collector
VBR Data Archiver
VBR DiagnosticCenter
VBR WebspaceDiagnostic Center
Analysis: transform engine data into
useful information to gain insight
Analysis: transform data into intelligent
engine alarm management to gain insight
Interpretation: VBR expertise & experience
draws conclusions from the insights gained
Feedback: provide operation & maintenance
decision support: recommendations & reports
Operation & maintenance
recommendations
Periodic engine health condition
reports
Periodic dialog with customer
on operation and maintenance
philosophy and strategy
Overview of RAPID options
Level A : Ad-hoc remote log-in for troubleshooting & problem solving
Level B : Continuous operations monitoring (reactive & corrective)
Level C : Intelligent diagnostics (pro-active, preventive & predictive)
Additional option : Consultancy, Training
Additional option : Helpdesk
Additional option : Remote corrective mapping
Summary
The most important factor in operating and maintaining gas turbines is the
human factor.
Every day decisions are made by gas turbine owners, managers, procurement
officers, operators and maintenance engineers that affect the performance,
reliability and profitability of gas turbine operations.
Human error is not individual error, it is a system error that requires a
systematic approach to achieve sustainable reduction.
The key to systematic and sustainable reduction of human error in gas turbine
operation & maintenance is a combination of education & training and a
dedicated decision support system for all decision making levels.
Questions?
Questions?
Thank you for your attention
Thank you for your attention.
www.vbr-turbinepartners.com
