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Imagination at work.
We are at your service for the life of your equipment Alberto Balbo, Asia Regional Manager – TM/CM&U, GE Power & Water’s Distributed Power July 2014
© 2014 General Electric Company – All rights reserved
© 2014 General Electric Company – All rights reserved.
A global delivered fleet... Jenbacher gas engines | Waukesha gas engines | Aeroderivative gas turbines
~37,000 Units 147 GW of Capacity >170 Countries ~5,000 DP employees helping our customers make power in more places
ADGT SOA| July 2014 2
© 2014 General Electric Company – All rights reserved.
>97%
Services that last a lifetime
Our life cycle management gives you the right service at the right time –
throughout the lifetime of your equipment.
ADGT SOA| July 2014 3
© 2014 General Electric Company – All rights reserved.
Chapter
GE’s maintenance
philosophy
Value-added services
& case studies
1 2 3 Aeroderivative gas
turbine maintenance
overview
ADGT SOA| July 2014 4 © 2014 General Electric Company – All rights reserved.
© 2014 General Electric Company – All rights reserved.
• Modular design and engine exchange Exchange major components fast… Reduces services downtime
• Condition based maintenance
Repair only as necessary... Allows balance between planned outages and life extension
• No starts penalty for mid-merit
or base load operation Lightweight design… Maintenance driven by engine condition
• RM&D
Remote troubleshooting and fast response… Reduces unplanned outages and improves performance
GE’s maintenance philosophy: Optional flexibility
1
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© 2014 General Electric Company – All rights reserved.
Modular design
– Major component exchanges
– Easier to handle and transport
– Rotors / stators nominally
– Ground for easy interchange
Split case design
– Compressor cases
– Ease of blade replacement
– Performed in the package
Hot section exchange
- Performed on site in minimum time
- Modules and tooling delivered to site
Engine exchange
- Target of 2 - 3 day outage with spare or lease engines
Modular design and engine exchange
ADGT SOA| July 2014 6
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Condition Based Maintenance (CBM): What and how?
“Condition-based” • Inspect and repair as necessary to
restore to desired operational condition
Condition determined by: • Bore scope inspection ports • Vibration data monitoring • Performance data monitoring • Lube oil filter and screen inspection • Lube oil analysis • External engine inspections • Re-start inspections and
operational check
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CBM: Aviation heritage Employed to manage and maintain highest levels of aircraft performance
Aviation engine
Aeroderivative turbine
• Common modular configuration as Aviation CF6
• On-condition maintenance • Moving from hours-based
intervals • Remote Monitoring & Diagnostics
(RM&D) + performance monitoring
• Six modules, fully interchangeable
(whole engine CBM) • On-condition maintenance
• No fixed engine time between overhaul
• 9 bore scope ports • In-flight engine condition
monitoring system
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© 2014 General Electric Company – All rights reserved.
Original
targeted outage
Inspection
Inspection Inspection
Check critical components for FOD, other anomalies
Assess deterioration rate to develop unit-specific trend
Inspection
Condition-based outage
reschedule Inspection
Check critical components Assess current condition relative
to CTO limits Reschedule outage based on projection
STOP - Projected condition at next inspection opportunity exceeds CTO limit – execute maintenance event as scheduled
CTO – Continue to Operate
Projected condition incorporates all available information including dynamics and operational profile
Check critical components Assess current condition versus CTO limits
Reschedule outage based on projected condition
CBM: Interval - outage optimization process
Timing of BOP maintenance also considered
Inspection Inspection
Original targeted
outage
Condition-based outage
reschedule Inspection Inspection
ADGT SOA| July 2014 9
© 2014 General Electric Company – All rights reserved.
RM&D
Faster and more efficient issue resolution
Mitigate event severity and frequency
Improved output, efficiency and capability
Elimination of repeat and systemic issues
ADGT SOA| July 2014
GE Aero RM&D Center, 24x7, Houston, TX
10
© 2014 General Electric Company – All rights reserved.
RM&D: Infrastructure and engagement map
Remote
Monitoring &
Diagnostics
Customer
Quick Response Center Proactive and reactive customer support from
GE experts
Distributed Power Portal Exchange of on-demand
information and data between customer and GE
Advisory / Reports Push notification based on
issues and subscription
Data
ADGT SOA| July 2014 11
© 2014 General Electric Company – All rights reserved.
RM&D: Facts
24/7 Monitoring Diagnostics
Helpdesk
200,000 incoming
datasets per hour
400 units connected
75 analytical
outputs per day
25 alerts processed
per day
OEM consultative
services
Top field engineers for
troubleshooting
ADGT SOA| July 2014
Tier 1
12
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RM&D: Quick Response Center (QRC)
QRC =
24 x 7 globally dispersed team staffed by field service and
controls experts
• Timely and enhanced technical support
• Immediate operational troubleshooting
• Proactive customer contact for RM&D generated urgent alerts
• GE internal escalation handling
• Remote mapping and emissions tuning
• Analysis of data-logs, trends, and alarm history
• Field technical direction and issue resolution
ADGT SOA| July 2014 13
Industrial Internet
Customer Benefits
- Proactive fault warning
- Outage diagnostic notifications
- Real-time viewing by off-site personnel
- Long-term trend analysis
- Remote troubleshooting
- Global network of GE experts on call
- Remote emissions adjustments
Remote Monitoring & Diagnostics
(RM&D)
- Centralized database
- Trending services
- Data access for remote users
Quick Response Center (QRC)
- Controls diagnostics
- Operability adjustments
- DLE mapping
+ =
“We have ended 2012 and 2013 with the best performance
ever in Songas’ history. We would like to thank GE’s QRC team
in responding to our needs in time,” Songas, Tanzania.
“We love to know that something
is breaking before it trips,”
Mondi, South Africa.
ADGT SOA| July 2014 14
© 2014 General Electric Company – All rights reserved.
Aeroderivative gas turbine maintenance overview
• Maintenance level • Typical scheduled maintenance • Bore scope inspections
• Engineering consulting • LM maintenance events
• Hot section • MOH • Engine exchange
2
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© 2014 General Electric Company – All rights reserved.
Maintenance level
Level I Preventative and corrective actions performed
on exterior of installed gas turbine (includes gas
turbine change out)
Level II Level I plus interior gas turbine actions performed
onsite
Level IV Complete disassembly and assembly of modules
and major assemblies. Allows replacement of any
individual piece part. Test capability required
Level V* Level IV plus repair of piece parts and control and
accessory items. (*Does not exist as single entity)
Onsite
Depot
ADGT SOA| July 2014 16
© 2014 General Electric Company – All rights reserved.
Typical maintenance schedule
4,000# Inspection (every 4,000 hours)* ~24 hours
25,000** Onsite hot section replacement ~3-5 days
50,000*** Depot refurbishment ~3 days
75,000** Onsite hot section replacement ~3-5 days
100,000*** Depot refurbishment ~3 days
125,000** Onsite hot section replacement ~3-5 days
Hours Scheduled Maintenance Action Outage
# For LM6000, interval is 4,000 hours, 450 starts, or once annual, whichever is first
* At 12,500 hours, LM6000 compressor bushings are replaced. ** Assumes gas fuel with water injection to 42ppm NOx. Higher water injection to achieve lower NOx levels may affect combustor life. DLE engines or SAC engines operating dry may see higher life spans. *** Spare or lease engine installed during refurbishment.
Actual time to conduct major maintenance still determined by hardware condition, not the actual hour count. *
ADGT SOA| July 2014 17
© 2014 General Electric Company – All rights reserved.
Bore scope inspections
Left side
Right side
Bore scope ports permit inspection of the entire gas turbine: All modules Frames Oil system and fuel nozzles
Digital transfer to the factory and engineering allows for real-time analysis
Bore scope inspections are required every six months/4,000 hours, or as directed by troubleshooting
Stage 13 port
Stage 13 port
ADGT SOA| July 2014 18
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LPC blades
DLE fuel nozzle
HPC S14 blades
HPT S1 nozzle HPT S1 blades
Samples of bore scope inspections
ADGT SOA| July 2014 19
OEM engineering consulting
Quarterly onsite meetings:
• Site walk by GE engineers
• In-depth discussion of major
RM&D/analytic findings within last
period and derived actions
• Site specific recommendations to
improve asset operation
Value:
• Take advantage of OEM know-how
locally
• Support and train customer
technical staff
ADGT SOA| July 2014 © 2014 General Electric Company – All rights reserved 20
© 2014 General Electric Company – All rights reserved.
• Exchange your Engine Component for a GE Engine Component
• Hot-Section Exchanges
– Repaired or New Parts Available
– 1 to 2 Day Outage
• Customer Benefits
– On-Site Service... No Shop Visit
– Less Downtime... 1 Shutdown
– Reduced Maintenance Costs
– Firm Price... No Surprises
– Fully Warranted Hardware
– Immediate Availability in most cases
– Light-Weight… easy to Handle & Transport
• Hot-section exchanges
– Repaired or new parts available
– ~ 3 day outage
• Customer benefits
– Onsite service... no shop visit
– Less downtime... 1x shutdown
– Reduced maintenance costs
– Firm price... no surprises
– Fully warranted hardware
– Immediate availability in most cases
– Light-weight… easy to handle and transport
– Includes required tooling, expendables, and onsite labor
LM maintenance: Hot-section exchanges
ADGT SOA| July 2014 21
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• Engine is removed from package
• Transferred to container
• Shipped to Service Center
LM maintenance events: Major overhaul
ADGT SOA| July 2014 22
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• Engine is removed from package
• Engine is shipped to Service Center for major overhaul
• Major overhaul inspection and repair
- Low/high pressure compressor
- Combustor assembly
- High pressure turbine
- Nozzle assemblies
- Low pressure turbine
- Hydraulic system, gearbox, VIGVs, VBV
LM maintenance events: Major overhaul
ADGT SOA| July 2014 23
© 2014 General Electric Company – All rights reserved.
LM maintenance events: Engine exchange
Minimized downtime during depot visits
• ~2-3 day outage with spare or lease engines
• Packages are designed for ease of engine removal
ADGT SOA| July 2014 24
© 2014 General Electric Company – All rights reserved.
GE’s value-added services and case studies
• Multi-year agreement (MYA)
• Aero on Demand
• Customer Cases
3
ADGT SOA| July 2014 25
Value-added services: Multi-year agreement (MYA) Team up to increase performance at lower cost
26
GE collaborates with you to achieve
your business goals
A service agreement is tailored to
complement your capabilities:
maintenance coverage,
performance guarantee,
operation support
GE’s expertise and operations
excellence are at your service
Reducing performance and
maintenance spend; improving
financial and operational planning
ADGT SOA| July 2014 © 2014 General Electric Company – All rights reserved
© 2014 General Electric Company – All rights reserved.
MYA options: Complete flexibility
Pick up the package that is right for you.
Full CSA MMP Framework
Outage Related Guarantees
Remote Monitoring & Diagnostics
Major Maintenance Scope & Cost Risk
Unplanned Maintenance
Service Bulletin Coverage
Performance Guarantees & Optimization
Major Maintenance Interval Risk
Integrated Lease & Engine Exchange
Pre-negotiated Terms & Conditions
Field Service Engineering & Parts Supply x
x Standard o Optional
x x
x
Level 3
x x
Level 1
x
x
x
x
x
o
o
o
o
o
o
Level 2
• Work scope − Gas turbines − Controls
− Package, gearbox, generators • Guarantees
− Availability, reliability, outage duration
− Output, efficiency • Payment
− Calendar-based fees (annual, quarterly, etc.)
− $/Fired hours − Milestone payments − Bonus/LD as executed
• Unit type and term − Any fleet age − Full range of operational
profiles
− Varying years, term, multi-cycles
ADGT SOA| July 2014 27
© 2014 General Electric Company – All rights reserved.
MYA: Growing capabilities
The past RM&D today Advanced
Services & MYA
Maintenance
intervals
Hours/starts based
or unplanned Condition based Rolling life prediction
Performance
relative to fleet
Backward look at
quarterly fleet data
Monthly reports
or on demand Available real time
Repeat issues Managed through
service bulletins
Managed by customer
portal access Predictive support
Unplanned events Break fix Basic analytics to predict
issues
Analytics based prevention
and site preparation
Output Fixed and facing asset
degradation issues Enabling ancillary services
Dynamic, cost based
capabilities
ADGT SOA| July 2014 28
© 2014 General Electric Company – All rights reserved.
RM&D case study: Downtime save
High Power Trip – downtime avoided, faster return to service
RM&D reported a High Power
Trip and multiple alarms
Within 15 minutes, QRC reached
out to the customer to offer
assistance and remotely
connected to site
QRC remotely checked engine
ABC mode, altered bulk
schedule, and brought unit back
into operation
RM&D
detection
RM&D
diagnosis
Action /
outcome
ADGT SOA| July 2014 29
© 2014 General Electric Company – All rights reserved. ADGT SOA| July 2014
Predictivity case study
Customer Metric Goals 2011
Actual 2012
Actual 2013
Actual
Start reliability >97% 97.3% 100% 99%
Availability (peak season) >98% 84.6% 99.7% 99%
Forced outage rate <1% 8% 0.10% 0.69%
Availability (total) >93.8% 80% 83% 94.7%
Preventative maintenance
• Onsite evaluations
• GE led maintenance planning • Service Bulletin prioritization • Outage workscope
Customer involvement
• Onsite O&M training
• Controls training • Monthly GE field service visit • Remote troubleshooting
Ongoing optimization
• My unit vs. Fleet comparison
• Spare parts/inventory • Tech docs and BOM access • Lease pool/asset mgmt.
Focused Implementation
RM
&D
inst
alle
d
30