dylan abel lead online systems engineer economic analysis...

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Economic Analysis with Platinum/AutoBalance® System on an Integral

Dylan AbelLead Online Systems Engineer

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Outline

Windrock Platinum System Components Site Background Information Site Platinum System Case Studies

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Platinum System

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Platinum System Controller

Collects, processes, and stores data for each input channel Makes the data available in Windrock MD and WebView for analysis Communicates Ethernet, Modbus, and RS-485

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Platinum Phase Conditioner

Provides timing signals to Platinum from magnetic pickups located on the machinery Supports both TDC and degree pickups Equipped with three relay outputs for OK, fault, and danger

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Platinum Power Supply

Converts 24 VDC from the field into power appropriate for each module Monitors the quality and quantity of the power delivered to each module Multiple power supplies can be used to provide redundancy

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Platinum Bay

Provides input channels for sensors in 16 channel increments 4 bays can be used in a system for a maximum of 64 channels Supports pressure sensors, accelerometers, proximity probes, temperature sensors, and

other standard 4-20 mA or voltage output sensors

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Platinum HMI

Provides a local touchscreen interface for the Platinum system in the field Displays live data using WebView

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AutoBalance®

Collects peak firing pressures from Platinum, processes, and adjust fuel valves as needed to keep an engine in equilibrium

Supports up to 10 fuel valves Multiple AutoBalances can be used for engines with more than 10 power cylinders Windrock holds a Patent for the AutoBalance

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Background Information

Roberts Ranch Gas Plant– Built in mid 1950’s by Cities Service Oil Company– Cities Service acquired by Occidental Petroleum in 1982– Duke Energy Field Services (later DCP Midstream) acquired plant in 1998 from Dynegy

Plant shutdown in 2005

Restarted in 2010 after complete overhauls on Units 11, 12, & 13 including “Lean-burn” modification with Jet Cells

AutoBalance systems installed December 2015/January 2016

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Units 11 & 12: Cooper Bessemer GMVH-10 with 4 compressor throws– 2000 HP @ 330 RPM– S/Ns 46810 & 46814– Built in 1967– 14” bore x 14” stroke– 1st and 2nd stage Propane– 2 cylinders Residue

Unit 13: Cooper Bessemer GMVH-8 with 4 compressor throws– 1600 HP @ 330 RPM– S/N 47791– 14” bore x 14” stroke– Single stage Residue

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Cooper-Bessemer GMVH

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Windrock Platinum AutoBalance Cabinet

System Controller Engine Bay

AutoBalance

Compressor Bay Phase Conditioner

Power Supply

HMI w/ WebView

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Platinum Compressor Monitoring

HE and CE Pressure X/H Vibration (G’s and IPS) Inboard and Outboard Frame Vibration (IPS and G’s)

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Platinum Engine Monitoring

Power Cylinder Peak Pressures

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Windrock AutoBalance AutoBalance Fuel Valves No modifications were made to the fuel system or jet cells

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Case Study #1

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Insert Customer logo Flow Balance Trend Plot

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Insert Customer logo Leak Index Trend Plot

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Insert Customer logo Data Playback

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Insert Customer logo Economics

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Insert Customer logo Case Study #1 Conclusion

Unit 13 Suction valve leak on Cylinder 1, CE began on 5/20/16 based on flow balance & leak

index. Based on limited experience, station had set a warning at 25 for Leak Index as the point

at which a leaking valve could be confirmed with valve cap temperature measuerements

Valve was replaced during shutdown from 7:20 am on 5/24/16 to 1:00 pm on 5/25/16

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Case Study #2

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Insert Customer logo Compression Pressure Trend

Power Cylinder 1-R

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Power Cylinder 1-RReplaced head gasket

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Unit 12 Compression pressure on power cylinder 1R lower than average Replaced cylinder head gasket during shutdown 5/3 23:00 to 5/4 1600 Comment: Cylinder 3L (higher than average) has miss-matched cylinder head (lower

clearance)

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Case Study #3

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Insert Customer logo PFP Trend Plot

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Insert Customer logo Power Curves

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Insert Customer logo Fuel Consumption

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Insert Customer logo Peak Pressure Trend

Re-connect plug wire

AutoBalance adjusts fuel valve

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Unit 11 Reconnected jet cell plug wire on 4-R 0n 5/19 @ 06:58 Low PFP on cylinder 4R generated warning alarm Operator went out to engine to investigate and found plug wire to jet cell disconnected Reconnected plug wire

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Case Study #4

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Insert Customer logo % Poor Combustion (30 cycles)

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Insert Customer logo PFA Standard Deviation

Power Cylinder 3-L Before Power Cylinder 3-L After

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Insert Customer logo Power Pressure Curves

Before

After

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Insert Customer logo GMVH Jet Cell

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Insert Customer logo Jet Cell

RemovedJet Cell

NewJet Cell

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Insert Customer logo AutoBalance Valve Position

Shutdown: Jet Cell Replacement

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Unit 11 Replaced jet cell cartridge on cylinder 3-L during outage 5/24 0400 to 5/25 0800 % poor combustions increasing

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Case Study #5

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Insert Customer logo Flow Balance Trend

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Insert Customer logo Leak Index Trend

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Insert Customer logo P-V Curves

Before

After

Suction Valve Replacement

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Insert Customer logo Cylinder 3 HE Capacity

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Unit 13 Replaced suction valve on 3 HE on 2/12 @ 1429

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Case Study #6

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Insert Customer logo Peak Pressure Sdev

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Insert Customer logo Live Power Parade Before

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Insert Customer logo Live Power Parade After

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Insert Customer logo Peak Pressures

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Insert Customer logo Fuel Valve Position

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Insert Customer logo Peak Firing Angles

Removed ignition timing offset for cylinder 5R

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Unit 11 Replaced Jet Cell on cylinder 5-R After re-start, AutoBalance adjusted fuel flow to compensate for better combustion Also, had to remove ignition timing offset that had been incorrectly applied to

compensate for bad jet cell

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Insert Customer logo Customer’s Economic Justification

Capital cost: $275,000 per engine

Payback:– Engine protection & lower maintenance costs: $250,000/yr– Longer overhaul interval (annualized per engine) $150,000/yr

Less than one year payback (~ 7 months)

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Insert Customer logo Customer’s Economic Justification

Other Benefits

10 – 15% Fuel savings (Average fuel flow reduced from ~360 MCF/day to ~310 MCF/day on GMVH-10)

Lower “Excess” emissions due to fewer unplanned outages

Higher detonation margins

Longer spark plug life (~ $7,000 per engine/year savings)

Lower mechanic, EA & operator labor-hours (~$600 per engine/year)

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Insert Customer logo Customer Integration w/ Station DCS

Data available to Operators

• Unit Average PFP• Engine Balance• Combustion Statistics• Unit Fuel Usage & BTU Value• Compressor Rod Loads• Total Compressor Indicated HP• Total Engine Indicated HP• Compressor Flow Balances & Leak

Indices• Crosshead Vibration• Frame Vibration

Shutdowns

• High Peak Firing Pressure (before detonation)

• High Vibration Levels (Frame & Compressor Throws

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Conclusion

Roberts Ranch is successfully using the Platinum/AutoBalance system to balance their engine and diagnose issues

When installing the Platinum/AutoBalance system DCP did not have to modify the fuel system or jet cells

Economics show that the payback period of the system is less than a year

dylan abel lead online systems engineer economic analysis...

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