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Towards the Future of Gas Turbine , reliability and asset management
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The gas turbine industry must focus on several key factors that will make
its future power generation technology successful in the electric power
generation market sector. These factors are as follows:
• competitive economic performance (i.e. higher efficiency and
optimised life-cycle cost);
• reliable operation under a cycle duty (repeated gas turbine startups
and shutdowns);
• increased dependability of current and future plants (reliability,
availability, maintenance and durability, or RAM–D);
• the ability to meet regulatory emissions levels and achieve high
thermal efficiencies; and
• reliable fuel-switching capability and fuel flexibility.
Gas turbines will be one of the most important horizontal technologies
and will play an essential role in meeting these requirements. It is
considered a horizontal technology due to its capacity to be integrated
into multiple power plant configurations, while running with different
fuels (coal gas, natural gas, hydrogen, liquid fuels, etc.).
The Spanish electricity utility Endesa is participating in the promotion of
initiatives to improve gas turbine technology, in particular the European
Turbine Network, which is dedicated to the application of highly efficient
and environmentally friendly technologies. Following the 3rd International
Conference on The Future of Gas Turbine Technology in Brussels, the
following conclusion can be made: “Gas turbine technology is one of the
best available options today and in the years to come for power
generation, however, they will continue to be affected or influenced by
their user´s technology and development needs pending resolution.”
This statement is reinforced by the fact that, in a deregulated and
increasingly competitive power generation market, power producers are
continually asking themselves, “How can we get the edge over our
competitors? How can we improve our decision-making processes?
How can we continually operate our plants in the most efficient and
cost-effective way? How can we limit damage and improve availability?
How can we reduce maintenance costs and extend service life? How can
we know fixed asset remaining value throughout power plant life?”
The key issues are the development of gas turbine assets and
performance management; these are the ways to achieve competitive
advantages that will enable companies to get the edge over their
competitors. The focus is therefore on gas turbine technology. The ‘hot
gas path’ of a gas turbine is the core of the engine, which includes the
combustion chamber, the transition piece and the turbine section. The
main drivers for improving hot gas path behaviour are:
• gas turbine performance – this is highly dependant on the turbine
entry temperature, which results in a greater need for the hot gas
path components to achieve high thermal efficiencies with low
nitrogen oxide (NOx) emissions; and
• gas turbine life-cycle cost – this is strongly affected by hot gas path
cost and maintenance, which gives rise to maintenance practices
and inspection techniques that in turn allow the improvement of
gas turbine dependability, i.e. its RAM–D.
Background
The blades and vanes in the turbine section will to a large extent
determine the ultimate efficiency of the gas turbine. These parts have to
work under extreme conditions, operating in high temperatures in an
oxidising environment while being subjected to large thermal and
mechanical stresses. In order to increase the durability of the blades and
vanes in these extreme conditions, special metal superalloys have been
developed. The high-quality technologies used in the manufacture of the
turbine blades make them the most expensive parts of the gas turbine.
In order to achieve higher thermal efficiencies, higher combustion
temperatures are needed; however, higher combustion temperatures –
from around 1540ºC (2,800ºF) – exacerbate NOx emissions. To combat
excessive NOx emissions, oxygen is limited during the combustion
process, but this can lead to unacceptably high levels of carbon
monoxide and unburned hydrocarbon emissions. Further adding to these
technological limitations, extremely high operating temperatures –
greater than 1,290ºC (2,350ºF) – are beyond the material tolerances of
the turbine blades and vanes.
Therefore, the goal of achieving 60% efficiency while staying below
10ppm NOx emissions is constrained by the thermal, emission
reduction and material limits of the gas turbine system. There are four
main innovations that are critical in meeting this need for high
efficiency and low emissions: closed-loop steam cooling; single-crystal
superalloy casting; thermal barrier coating; and lean pre-mix dry low-
NOx combustors. In order to optimise the life-cycle cost of gas turbines,
special attention must be paid to the hot gas path components:
typically, around 70% of the total maintenance cost corresponds to
schedule, maintenance, parts and materials. This will lead to the
establishment of mechanisms for risk mitigation, such as long-term
service agreements (LTSAs), business interruption insurance, extended
guarantees and part-cost guarantees. Apart from the above
Towards the Future of Gas Turbine Asset and Performance Management
© T O U C H B R I E F I N G S 2 0 0 7
Turb
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Dr Tomás Alvarez Tejedor is Head of the EndesaCombined Cycle Technology and Maintenance
Department. He has been working in the Spanishelectrical market for more than 15 years, covering R&Dprojects on advanced power generation systems, asset
management and combined cycle power generation andgas turbine technology. Dr Alvarez obtained his BSc,
PhD and MBA at the Polytechnic University of Madrid,his MSc in the Gas Turbine Engineering Group at
Cranfield University, and his postgraduate specialisationon the Spanish electrical sector at Carlos III University.
a report by
Tomás Alvarez Tejedor
Head, Combined Cycle Technology and Maintenance Department, Endesa Generación
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P O W E R I N D U S T R Y I N T E R N A T I O N A L 2 0 0 720
Towards the Future of Gas Turbine Asset and Performance Management
considerations, it is also necessary to take into account current
operational conditions in a deregulated electricity market. These
conditions require more flexible operations with high efficiency and
low emissions for the whole power range, high operational reliability
and better maintainability.
Hot Gas Path Management
From the condition monitoring, instrumentation and control
standpoint, many improvements can be made to hot gas path
management. The ultimate goal is to manage the hot gas path section
by knowing its condition (known as condition-based maintenance, or
CBM) and its performance (known as performance monitoring). In
order to get in-depth knowledge of the condition of the hot gas path
components, it is necessary to combine both online and offline
techniques: together, these will show the real status of the main
components of the hot gas path section. In order to look at these
subjects in more depth, we need to divide the process into different
levels that allow us to set the needs assessment findings for each.
Level 1: Sensor Level
Typically, gas turbine units are equipped with minimal instrumentation.
On the one hand, this means the supplied sensors are adequate to ensure
safe operation and to monitor performance and emission requirements,
but on the other hand these units are not equipped with any
instrumentation that would provide the ability to: optimise performance;
define the risk of extending operating periods; monitor component
degradation; provide early warning of faults in the system; and monitor
hot section environment and failure mechanisms. In terms of needs
assessment findings, the following diagnostic instrumentation is required:
• combustion pressure pulsation;
• flame temperature sensors (semiconductor photodiode);
• fuel low-heating value (LHV) measurement (LHV sensor);
• turbine blade surface temperature (optical pyrometers);
• turbine blade vibration (optical probes);
• turbine blade tip deflection (blade tip clearance sensor);
• air inlet mass flow (ultrasonic sensor);
• turbine circumferential inlet temperature distribution (optical
fibre thermometers, high-temperature research and technology
development); and
• coating life degradation sensor (odometer, infrared sensor).
Level 2: Control and Supervision
Once the output from the instrumentation has been acquired, it can be
input into the local unit’s control station, which consists of a PC
equipped with Original Equipment Manufacture (OEM) software. This
provides the operator with a series of windows-based viewing screens
that present measured and calculated data. Factored starts and hours
are determined by empirical formulae provided by OEM. The power
industry is not completely comfortable with this approach due to higher
than desirable maintenance costs for gas turbines, and generally does
not have confidence in OEM’s stated hot gas path component life and
replacement interval. The industry would prefer to have a more
machine-specific, condition-based approach to determining the timing
of maintenance. As a result, control systems play a critical role in data
collection, conditioning and analysis within the automated CBM
infrastructure. Advanced process control systems include analysis
algorithms that enable them to diagnose and report malfunctions to the
CBM system. This ultimately supports system-wide asset management.
In terms of needs assessment findings, the following information
technologies are required for data manipulation:
• Online data acquisition – the data acquisition module provides
system access to digitised sensor or transducer data. It may
represent a specialised data acquisition module that receives
analogue feeds from sensors, or it may collect and consolidate
sensor signals from a data bus.
• Data processing and validation:
• signal-processing approach:
• signal correlation;
• high pass filtering; and
• correlation matrix and response statistics.
• physics-based approach:
• correlation matrix and response statistics;
• statistical neural network; and
• fuzzy logic rule based.
• Data-fusion techniques – a formal framework used to express
convergence data from different sources and the means and tools
for the alliance of these data.
• Data-mining tools – these provide new insights into wear and
failure mechanisms in engine components:
• neural nets;
• statistical analysis; and
• generic algorithms.
• Advanced control algorithms:
• predictive control algorithms for combustion instability;
• adaptative controller;
• closed-loop steam cooling control;
• active control technologies for enhanced performance,
enhanced reliablity and reduced emissions;
• fault-tolerant engine control (smart sensors and actuators); and
• closed-loop optimisation.
Level 3: Condition Monitoring
The primary function of the condition monitor is to compare features
against expected values or operational limits and output enumerated
condition indicators (e.g. level low, level normal, level high, etc.). The
condition monitor may also generate alerts based on defined operational
limits and, when appropriate data are available, may generate
assessments of operational context (current operational state or
operational environment). Ultimately, this would lead to automatic
assessment of the condition of the hot gas path section, thereby
reducing human inspection tasks and the unnecessary maintenance that
occurs in a traditional periodic maintenance scheme. System assessment
would also provide valuable realtime decision support data for
operational planning. In terms of needs assessment findings, one of the
unmet needs at this level is component life monitoring, either through
direct or indirect monitoring of component properties:
• Online monitoring of component life would allow some
assessment of when the next shutdown might occur.
• Online indication of component degradation could alert operators
to failures that could propagate through the unit. For example,
online monitoring of the combustor status or blade coating
integrity would alleviate downstream consequences.
• Offline non-destructive evaluation (NDE) of component life would
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Towards the Future of Gas Turbine Asset and Performance Management
help determine if component replacements are needed before the
next scheduled shutdown:
• eddy current metallic coating life (aluminium depletion versus
conductivity); and
• time-base corrector (TBC) integrity (NDE methods).
• NDE measurements and supporting analysis to determine:
• physical condition of components referenced to baseline;
• cyclic fatigue status of components; and
• component coating wear and integrity status.
• Online assessment of the risks of extending the outage schedule
would also be useful to determine whether it is possible to operate
for extended periods.
• Sensors that map the blades and vanes for integrity. For example,
a temperature profile of the blades and vanes could indicate
blocked cooling passages or coating failures.
• Online monitoring of exhaust gases for metal particles.
• In situ repair technologies (TBC repair).
Level 4: Performance and Health Assessment
The primary function of the performance and health assessment level
is to determine whether the health of a monitored system, subsystem
or piece of equipment is degraded in terms of its thermodynamic and
mechanical condition. If its health is degraded, this assessment level
may generate a diagnostic record that proposes one or more possible
fault conditions with an associated confidence. This level should take
into account trends in the health history, operational status and loading
and maintenance history of the system, subsystem or piece of equipment.
The needs assessment findings are as follows:
• Combustion process diagnostic module – automated assessment
of exhaust gas temperature (EGT) spread, fuel flow manifold and
supply pressure, vibration/dynamic pressure, emission data, etc.
• Hot gas path analysis – determination of hot gas path condition
based on the thermodynamic relationships that exist between the
engine components and various gas path performance parameters.
• Hot section damage assessment – automated trending and fault
pattern classification and fusion.
• Aero-thermal performance-based module.
Level 5: Prognostics
The primary function of the prognostics level is to project the current
health and performance state of equipment into the future, taking into
account estimates of future usage profiles. The prognostics level may
report health and performance status at a future time or may estimate
the remaining useful life of an asset given its projected usage profile.
Assessments of future health or remaining useful life may also include a
diagnosis of the projected fault condition. Prognostics therefore allow us
to predict the onset of hot gas path component failure to match its use
or to enhance maintenance support. Prognostic capabilities expand
support options and allow for cost-effective planning and management.
The needs assessment findings are as follows:
• Life consumption tracking module of hot gas path components:
• assessment model for coating degradation;
• assessment model for creep fatigue damage; and
• assessment model for thermal mechanic fatigue.
• Hot gas path components life-cycle prognostics.
• ‘What if’ analysis for the performance and health of the hot gas
path components.
Level 6: Decision Support
The primary function of the decision support module is to provide
recommended actions and alternatives and to advise on the implications
of each recommendation. Recommendations include maintenance action
schedules, modifications to the operational configuration of equipment in
order to accomplish mission objectives or modifications to mission profiles
to allow mission completion. The decision support module needs to take
into account operational history (including usage and maintenance),
current and future mission profiles, high-level unit objectives and resource
constraints. The needs assessment findings are as follows:
• Computer-based gas turbine condition- and health-monitoring
predictive systems might offer the potential for providing decision
support for the following items:
• reduced nuisance shutdowns and unplanned outages;
• optimum engine operation;
• continuous realtime maintenance scheduling;
• extended time between overhauls based upon determination
of remaining component life;
• protection against catastrophic failure via realtime fault
assessment; and
• estimating operations and maintenance (O&M) cost based on
condition monitoring.
• Automated logistics for advanced scheduling and co-ordination of
maintenance actions. Advanced triggering of logistics support
improves system availability and utilisation of resources.
Level 7: Human Interface
Typically, high-level status reports (health assessments, prognostic
assessments or decision support recommendations) and alerts would
be displayed at this level, with the ability to access information from
lower levels when anomalies are reported. In many cases, the human
interface level will include multiple layers of access depending on the
information needs of the user. The needs assessment findings are:
• More user-friendly human interfaces are required to supply
actionable information to the operator and maintenance staff:
• actionable information provides users with the necessary
details for effective decision-making; and
• actionable information should be in the form of ‘what
happened, where, when, how bad is it and what should be
done about it?’.
Conclusion
Future advanced thermal power plants will need to be highly complex
in order to fulfil the requirements of a global society that is increasingly
sensitive to environmental issues. Gas turbine technology will play a key
role as the core technology for different plant configurations. Gas
turbine asset and performance management will allow the industry to
develop the competitive skills required for the new power generation
arena, with the aim of optimising life-cycle cost by improving both gas
turbine dependability and performance. ■
A longer version of this article, containing graphics, can be found
in the Reference Section on the website supporting this briefing
(www.touchbriefings.com).
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