MODERN MONITORING TRENDS OF GAS TURBINE FLEET
Felix A. Gaisin
Head of Reliability Department, Aviadvigatel OJSC.
Doctor of Technical Science
Eduard R. Artikulov
Deputy Head of Computer-Aided Control Systems and Production Preparation Department, Aviadvigatel OJSC
Forewarned is forearmed. Information about technical state of gas turbine equipment operated at customers' facilities has always been a great value for designers, producers and operators. Only full and timely information allows to solve quality problems appearing during equipment operation, to perform maintenance and overhaul in time, to modify the design in order to increase its safety, reliability and efficiency.
Indexes of the equipment failure-free operation and reliability were measured on the basis of data sent by operating companies.
The comparison of these indexes have given an opportunity to estimate the performance efficiency of equipment, engineering and production staff.
Aircraft engine performance assessment criteria are also successfully used for industrial gas turbine equipment. Reliability factor calculaton procedures developed in Central Institute of Aviation Motors (CIAM) were supplemented with Gazprom researches.
Computer equipment progress led to the development of varies software for indexes calculation. The recent one was created on the basis of MS Exel. It allows to calculate reliability factors based on final data calculated manually.
Presently based on the technical requirement of Reliability Department the specialists of Computer-Aided Control Systems and Production Preparation Department have developed an information system which makes it possible to accelerate the data processing significantly.
The information system is based on Arkhived digital documents storage system and is implemented as its additional application. This allows to use the Arkhived functional to perform general functions (installation, users data base support, right of access and usage monitoring) and to keep archives.
System builtin functions provide rich opportunities for search and random selection on the supported archives.
An additionally created system consists of the following modules:
- Gas Turbines, Engines and Their Total Running Time Guide;
- Standard Defects Guide;
- Analytical Module;
- Reports Preparation Module.
The purpose of the information system is to provide the Development Design Bureau specialists and cooperating companies, if necessary, with the following data:
1. Accounting of:
- engines and repair works;
- engine total running time incl. after repair;
- engine movement at sites;
- on-site failures of engines, units and system with their classification (defects archive);
- results of production gas turbines analysis in the Design Department of parts inspection (KOID) of Perm Engine Company OJSC, (report archive);
- measures developed by designers and manufactures in accordance with engines, units and systems defects.
2. Reliability factors calculation results.
3. Data on total running time, defects, reliability factors as well as information on KOID's reports in various forms ( report, diagram, set pattern with different random selection parameters in a file or printed).
Gas Turbines Guide contains detailed information on engines including their total running time, integration to a gas turbine,
location places etc.
A data processing with the help of the information system is performed as follows. At the preliminary stage a gas turbine guide is created. It consisting of 3 parts containing data on new and repaired engines, their total running time etc. For the system users' convenience engines are integrated with gas turbines, operators and places of dislocation. When information on engine movement in operation and their total running time appears the Reliability Department specialists correct the data in the gas turbinegGuide and register data on every defect in a formalized sheet. Defects data is recorded in the defects archive.
More than 35 parameters of defect are described herewith. Based on any parameter combination one can search defects (do random selection), save for further use or print. In the guide it is possible to receive any information about total running time, operators and so on using parameters filter. For instance, one can find out the total running time within a certain period for a specified dislocation, operator and engine. All the data in the system is interconnected and not duplicated.
The defect archive is correlated with the engine and gas turbines guide, total running time guide and standard defects guide. The last guide is interesting due to the fact that it provides the defect integration with a standard failure and also it can give full information on this defect and taken measures. All specialists authorized in the system can use the given data in their work (more than 50 parameters in the whole) and they are provided with full and reliable information on engines in operation and correspondent reliability factors.
To get the necessary information easily two modules are formed: an analytical module and a report module. These modules allow to make a request and to receive information in a form of reports, tables and diagrams using defects database, gas turbine guide and defects data.
The modules provide with:
- summary data on the quantity of engines and gas turbines in operation for the fleet, operator and dis-location within different periods;
- summary on engine total running time within a spe-cified period incl. total run-ning time for the operator`s fleet, dislocation and any other group;
- various analytical data on engine reliability;
- information on engine history (defects and total running time);
- information in a form of special reports;
- information from files filled-in by the system in a form of templates.
Information about every gas turbine defect is recorded in a formalized sheet.
The analytical module and the report module give information on gas turbine operation in a form of reports, tables and diagrams.
Specialists from the Reliability Department of Aviadvigatel OJSC continuously enlarge the information system. At present a digital database about industrial gas turbines operation is nearly completed. It provides the developer with a complete image of gas turbines fleet state during the whole period of operation.
Further development of information technologies and their mastering by operators followed by transfer of data on industrial gas turbines to Aviadvigatel, OJSC can widen the software capabilities and ensure gas turbines on-line monitoring.
It is important to underline that this system allows to transfer information on Perm gas turbine equipment operation simultaneously to all operators, including Gazprom, OJSC, Rosneft NK and others to create a true-to-life picture.
Available information about actual reliability performance of gas turbine equipment promotes further advance of Perm gas turbines in the domestic and world market. Besides the software interface can import data and can be integrated with FRACAS (Failure Reporting and Corrective Actions System) which is widely used in the after-sale service networks of West European countries. FRACAS application will make it easier to certify products developed by Aviadvigatel OJSC in accordance with standards approved on the territory of Europe and other countries.
