0PREVENTIVE MAINTENANCE PROGRAM AND NOVEL TECHNIQUES TO REDUCE

DOWNTIME AND INCREASE OPERATING EFFICIENCY AT DISTRIBUTED COGENERATION FACILITIES

Dorin Scheianu and Tom LeWood Group GTS, Houston

IDEA 2013 February, San Diego

1SUMMARY

Gas Turbine Maintenance Total Plant Service Optimization Concept

Case study: Turbine Upgrade - Rady Childrens Hospital (San Diego) Case study: Turbine Analysis Tools - Rice University (Houston)

Preventive maintenance and data analysis designated to better diagnosing turbine condition and planning term maintenance services

IDEA 2013 February, San Diego

2PURPOSE OF GAS TURBINE MAINTENANCE

Maintain plant availability, reliability and component life expectancy Maintain plant performance (power and specific fuel consumption) Maintain optimal tuning Keeping compliance with applicable regulations Keeping all possible operating options for the owner Allowing for applicable hardware (including turbine) and software

upgrades for safety, reliability and performance

Allowing analysis of operation with the purpose of continuously improving plant parameters

IDEA 2013 February, San Diego

3TOTAL PLANT SERVICE OPTIMIZATION CONCEPT A SERVICE PROVIDERS AGENDA

Mobilization and Operational Services Site inventory Site Systems Manuals and Training Operational Procedures Manual Computerized maintenance management system Administrative procedures program Operator qualification program Additional services

IDEA 2013 February, San Diego

4IDEA 2013 February, San Diego

Case Study - RADY CHILDRENS HOSPITAL

FACILITY SUMMARY

DTE Energy San Diego, LLC. established to

provide O&M services to Rady Childrens

Hospital of San Diego. Rady Children's

Hospital-San Diego is the regions pediatric

medical center serving San Diego, Imperial,

and southern Riverside counties.

5RADY CHILDRENS HOSPITAL

IDEA Conference Rady Childrens Hospital

The largest children's hospital in California (based on admissions)

The sixth largest children's hospital in the country

The only hospital in the San Diego area dedicated exclusively to pediatric

healthcare

The region's only designated pediatric trauma center

Provider of care to more than 82 percent of the regions children

Provider of care to more than 150,000 children in 2011

Outstanding team includes nearly 700 physicians and more than 1,000 nurses,

nearly 4,000 employees, 450 active volunteers, and more than 1,200 auxiliary

members.

6The Project

DRIVERS FOR PROJECT DEVELOPMENT

New facility commissioned in 2011, demanding additional power and heat New hospital equipment requiring sudden excursions in power of 700 kW Need for reliable and uninterrupted power (35+ life saving surgeries

performed daily, out of a total of 200+) Need for margin to max load, to ensure uninterrupted operation Need for process efficiency Compatibility with the existing equipment and installations already the

boiler and subsequent cogeneration existing with no intent to be replaced) Short time for completion, involving all of the following:

Mechanical installation Electrical installation and controls changeover Specific auxiliary equipment changeover Tests and commissioning

Long term service contract with service provider

7The Project

PROJECT SCOPE

Replacement of the existing gas turbine Centaur 40 with a Taurus 60

Replacement of main reduction gearbox Replacement of control software Maintaining the existing electric generator Maintaining the existing skid Maintaining the existing electrical installation Making all mechanical and electrical adaptations Addition of an acoustics monitoring system for the new combustor Commissioning the new turbine Addition of a remote control access system (under development)

8Equipment Layout

Natural Gas

Hot Water 400 F

Chilled water 33 F

Steam 76 psig

Absorption cycle

Exhaust gas 860F

9Project Overview

One (1) Solar gas fueled turbine generator package

This unit was purchased new with a Centaur 40S turbine engine and commissioned by Solar Turbines in 2002.

Turbine Generator package was upgraded by Wood Group to T7901S turbine engine in August 2012.

PROJECT SUMMARY

Specification Centaur40 Taurus60

EngineID T4701S T7901S

SerialNo. OHJ08C0841 N/A

ISOPower(G) 3516kWe 5513kWe

NGP(RPM) 1495160Hz 1495160Hz

IGVSetting +8.0DEG +7.0DEG@59F

T5Base(G) 1104F 1290F

T5SetPoint(G) T51170F T51250F

EmissionSP(G) 1132F 1230F

%Pilot(G) PartLoad 3 4

%Pilot(G/L) FullLoad 2 3

10

Project Execution

Centaur 40 Performance Generation Power: 3516 kW rated /

2800 kW typical, no capability for sudden excursions in power demand

Exhaust Temp: 860F quasi constant Heat Recovery Primary Production:

Hot water 400 F Secondary usage of recovered heat:

steam 76 psig, cold water 33 deg. F Low Emissions

TIMELINE FOR EXECUTIONRemoval & Installation Start Date

August 3rd, 2012

Testing, commissioning and Hand Over Date

August 9th, 2012

Total Duration 6 Days

Taurus 60 Performance Generation Power: 5513 kW ISO rated,

3200 kW typical with sudden excursions up to 4700 kW

Exhaust Temp: 960F quasi const. Heat Recovery Primary Production:

Hot water 400 F Secondary usage of recovered heat:

steam 76 psig, cold water 33 deg. F Low Emissions

11

Project Execution

New turbine after installation

12

Turbine Up-Rate Benefits

Centaur 40 to Taurus 60 Conversion

No change in operating and management costs Rated power: increase by 57% Typical operating power: increase from 2800 kW to 3200 kW Maintenance Cost: increase of service contract fee by 33% Fuel Cost per kW: reduction, due to better efficiency Heat recuperated: better quality, due to higher exhaust temperature. Actual

operation of new turbine ensures quasi constant exhaust temperature at variable exhaust flow. New operation is perceived as ensuring an increase in hot water production.

Total blackouts were eliminated

OPERATIONS & MAINTENANCE COSTS AND BENEFITS

13

Remote Monitoring

REMOTE CONTROL ACCESS, MONITORING AND DIAGNOSIS

Part of a quality long term service agreement Monitoring early changes of equipment health

indices and supplying proper maintenance as deemed necessary

Monthly (typical), weekly or daily (if needed) turbine health monitoring reports

Better scoping and planning of next scheduled term maintenance

Additional help when solicited Optional help from the service provider, when

opportune Remote tuning of control parameters, when such

service is appropriate

14

Analysis Tools

SPECIFIC SITE CONDITIONS-AMBIENT TEMPERATURE

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T1ambient,histogram,Rice

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AmbienttemperatureT1,deg.F

T1ambient,Rady

Ambient temperature profile is site specific and extremely well differentiated

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Analysis Tools

MONITORING DATA

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kW

Histogram,Outputpower,Rice

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kWe

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kWe

Histogram,outputpower,Ref.Unit2 Operating profile depends of

many objective and subjective factors

Unit 1 and Unit 2 although identical and in parallel, have different operating profiles

16

Analysis Tools

MONITORING DATA

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T1amb,deg.C

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kWe vs.T1,alldata,Rice

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kWe vs.T1,alldata,Ref.Unit2 Typical indicators: kWe, CDP, SCF, TTex Each regressed at baseload(function of T1) or at any load (function of T1 and % command)

Deviations actual to expected matched to most common faults

Appropriate maintenance scoped and scheduled at nearest term service

17

Analysis Tools

MONITORING DATA

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CDPvs.T1,alldata,Ref.Unit2 CDP is a direct health indicator for turbine compressor

It is well known that periodic service is required

It is also related to the air inlet filter house

Easier to assess baseload data, more complex based on all data

18

Analysis Tools

MONITORING DATA

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1.051.1

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2/1/2012 4/2/2012 6/2/2012 8/2/2012

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kWratio,RiceUniv.

kWRatio

Ratio of kW actual / kW expected at baseload makes easy to assess significant changes in engine performance and helps reveal possible causes

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Analysis Tools

MONITORING DATA

y=21x+5550

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kWe vs.T1,baseload,RiceUniv.

y=31.275x+5179

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kWe vs.T1,baseload,Ref.Unit1

y=31.275x+5179

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Tamb,deg.C

kWe vs.T1atbaseload,Ref.Unit2 Regression of parameters at baseloadvs. ambient temperature

Regression parameters are specific to each turbine

Differentiation of effects kW as overall parameter, CDP, TTex, T5 spread and SFC allow differentiation between turbine components

20

alysis Tools

MONITORING DATA

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T7

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2012 3/22/2012 5/11/2012 6/30/2012 8/19/2012

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PCDRatio

kW

21

alysis Tools

MONITORING DATA

Specific Fuel Consumption is extremely sensitive to any degradation occurring inside the turbine

Care should be taken to consider effects of load change besides ambient temperature

0 1000 2000 3000 4000 5000Generatoroutput,kW

SFC,Btu/kWHR,Rice

y=0.001116x2 9.912x+3239

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y=17.678x+9351.8

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SFCBaseloadT1,Rice

22

EA 2013, February, San Diego

APPLYING TECHNICAL EXPERTISE AND SKILLS AT SCHEDULED TERM MAINTENANCE AND BETWEEN INTERVALS BY REMOTE

MONITORING

Borescope inspections Vibrations data collection and analysis Remote monitoring and real time performance analysis, with real

time plot of multiple engine health indicators

Combustion Dynamics monitoring and automatic corrective actions Periodic maintenance

23

EA 2013, February, San Diego

CONCLUSIONS

as turbine maintenance is a key service to providing steady performances, high

vailability and reliability for the equipment. As important as initial design and

ubsequent upgrades

otal plant optimization concept

ase study: Turbine upgrade - Rady Childrens Hospital (San Diego) cogeneration

cility

ase study: Turbine analysis tools - Rice University (Houston)

reventive maintenance and analysis designated to better planning term

aintenance services. Daily, weekly and monthly visual reports generated

utomatically.