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MAN | PrimeServ

Optimisation Of Gas Turbine Compressor Trains

By Online Monitoring

Holger Berghaus

Brussels, October 2016


MAN | PrimeServ

1 MDT GT‘s - Overview

2 Monitoring System

3 Current Developments

4 Summary


MAN | PrimeServ

Oldest one from 1968

Power 3-25MW

MDT GT‘s - Overview


MAN | PrimeServ MDT GT‘s - Overview

Data Collector

Installations save cost!


MAN | PrimeServ


2 Monitoring System


4 Summary


MAN | PrimeServ

Source: PrimeServ Turbo project team

Monitoring System


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Machine Data

Speed & VGV position

Shaft vibration & axial

displacement

Bearing-, casing- and

differential temperatures

Voltage, current, power and

winding temperatures of motor

Process Data

Pressures, temperatures and

mass flow at inlet & outlet of

each stage group

Ambient conditions

Auxilliaries Data

Pressures and temperatures

Differential pressure at filter

elements

Coolant temperature and

pressure

Controller inputs and outputs

Position feedback

Mechanical condition of each

machine

Operating point in characteristic

curve

Efficiency

Operating point in characteristic

curve

Degradation of internals

Efficiency

Mechanical condition of coolers

and filters

Degradation of coolers and

filters

Efficiency of auxilliaries

Control logic

irds® Basic Parameters

Resulting analysis

Monitoring System – Capabilities


MAN | PrimeServ

-0,5

-0,4

-0,3

-0,2

-0,1

0

0,1

0,2

0,3

01.01.03 21.01.03 10.02.03 02.03.03 22.03.03 11.04.03 01.05.03 21.05.03 10.06.03 30.06.03

measured axial position [mm] calculated lower / upper limit local alarm set point

difference between lower and upper alarm set point: 0,6 mm

difference between lower and upper calculated limit: 0,1 mm

difference between minimum and maximum measured value: 0,2 mm

calculated dynamic limits,

adopted to operating state

Monitoring System – Data Analysis


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Message of limit violations to nominated

PrimeServ engineer

& trending of deviations

with adams plus

( automatic data analysis and message system )

Operating value exceeds dynamic limit

Monitoring System – Data Analysis Remote


MAN | PrimeServ

Libya 2003: Customer informs about

vibration trip, site inspection reveals

GG compressor damage.

Fleet: Compressor blading with more

than 2 billion operating hours.

Analysis of operating data shows

frequent message of GG-speed

being on upper limit – unusual for

this climate.

Monitoring System – Examples


MAN | PrimeServ Monitoring System – Examples


MAN | PrimeServ

Gas Turbine

(peaking genset)

trips via surge

detection or

overtemperature.

Data conncection

not available

=> 2 engineers fly

out.



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30°F ~ 0°C

Cayman Island?




Enhanced analysis with further tools

statistical analysis:

rate of operating time within curve

analysis of properties:

efficiency, vibration, etc. versus curve


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2 Monitoring System


4 Summary


MAN | PrimeServ

Source: PrimeServ Turbo project team

Monitoring System – Overview & Areas of Development


MAN | PrimeServ Current developments – 1 – Improving Monitoring

Dynamic Limits currently:

Neural Networks:


MAN | PrimeServ Current developments – 2 – Always the Server?


MAN | PrimeServ Current developments – 3 – No Data Outside


MAN | PrimeServ


2 Monitoring System


4 Summary


MAN | PrimeServ Summary

1. The installation of a data collecting system saves more than it costs. This is

why MAN Diesel & Turbo does it since 1999 for all gas turbines.

2. Flexibility is key, gas turbine & driven machine may be only part of an

installation.

3. In our experience, central analysis is a “must have” but analysis capabilities

will have to be expanded for direct at site availability.


MAN | PrimeServ

All data provided in this document is non-binding.

This data serves informational purposes only and is especially

not guaranteed in any way. Depending on the subsequent

specific individual projects, the relevant data may be subject

to changes and will be assessed and determined individually

for each project. This will depend on the particular

characteristics of each individual project, especially specific

site and operational conditions.


MAN | PrimeServ

Thank You For Your Attention

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